Factory Workshop Manual
Make
Ford
Model
Explorer 2wd
Engine and year
V6-4.0L (2009)
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This manual was submitted by
Anonymous
Date
1st January 2018
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory
Delay Module > Accessory Delay Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory
Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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
^ 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 (V6-4.0L (2009))
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 23
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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
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 (V6-4.0L (2009))
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 29
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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
^ 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 (V6-4.0L (2009))
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 40
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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
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 (V6-4.0L (2009))
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 46
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 (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM)
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Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) >
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Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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)
Part 1
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Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) >
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Part 2
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Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) >
Page 53
Communications Control Module: Diagrams Audio Control Module (ACM)
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Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) >
Page 54
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) >
Page 55
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Service and Repair > Procedures
Communications Control Module: Procedures
Accessory Protocol Interface Module (APIM) Software Level Check
Accessory Protocol Interface Module (APIM) Software Level Check
NOTE: This procedure applies to checking the Accessory Protocol Interface Module (APIM)
software level. To program the APIM, refer to Accessory Protocol Interface Module (APIM)
Programming in Information Bus. See: Powertrain Management/Computers and Control
Systems/Information Bus/Testing and Inspection/Programming and Relearning/Accessory Protocol
Interface Module (APIM) Programming
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 software level.
- The display shows both the Vehicle Interface Processor (VIP) and Consumer Interface Processor
(CIP) software levels.
8. The scan tool displays the following information:
- Last Recorded State - Hardware VIN: vehicle identification number associated with the current APIM
- Installed date: date the APIM was installed
- Radio: currently identified ACM in the vehicle
- HW Part No.: APIM hardware part number
- Un-installed date: date (if any) the APIM was uninstalled
- S/N: APIM serial number
- Last Recorded State - Software Date/Time: date and time of last recorded software installation
- VIP: VIP software that was installed at that time
- CIP: CIP software that was installed at that time
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- Description: a description of the content of the software revision
- History - Software Date/Time: date and time of any recorded software installation
- VIP: VIP software that was installed at that time
- CIP: CIP software that was installed at that time
- Description: a description of the content of the software revision
- Available Software for Programming Select: allows the software package to be selected
- Lineage: the original software release, if the software available is a revision
- VIP: VIP software level that is available with the selection
- CIP: CIP software level that is available with the selection
- Description: a description of the content of the software revision
9. Click a CIP software level to view the device compatibility list associated with the CIP software
level, if desired.
10. To exit the APIM software level check, disconnect the scan tool from the DLC and the USB
port, or exit the OASIS screen.
Audio Control Module (ACM) Self-Diagnostic Mode
Audio Control Module (ACM) Self-Diagnostic Mode
Audio Systems Without Navigation
1. Turn the Audio Control Module (ACM) on.
2. Operate the audio system in radio tuner (AM/FM) mode.
3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins.
- The display indicates each speaker as it is tested.
4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after Step
3 by turning the ACM off.
Before the speaker walk test is complete, carry out any of the following actions:
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Communications Control Module > Component Information > Service and Repair > Procedures > Page 59
5. To exit the self-diagnostic mode, turn the ACM off.
Satellite Digital Audio Receiver System (SDARS) Module Electronic Serial Number (ESN) Retrieval
- Vehicles Without Navigation
1. Operate the audio system in satellite radio mode.
2. Press and hold the AUX button and preset button 1, simultaneously.
- The Satellite Digital Audio Receiver System (SDARS) module Electronic Serial Number (ESN)
displays on the screen.
3. Record the SDARS module ESN.
4. Turn the audio system off.
Audio Systems With Navigation
1. Turn the Audio Control Module (ACM) on.
2. Operate the audio system in radio tuner (AM/FM) mode.
3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins.
- The display indicates each speaker as it is tested.
4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after this
step, or by allowing the speaker walk test to
complete on its own.
Before the speaker walk test is complete, press the "End Test" selection.
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5. The following tests are available through the "BEZEL DIAGNOSTICS" menu:
6. To exit the self-diagnostic mode, press the "Exit Diagnostics" selection from the "BEZEL
DIAGNOSTICS" menu.
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Communications Control Module: Removal and Replacement
Audio Control Module (ACM)
Audio Control Module (ACM)
Removal and Installation
NOTE: It is not necessary to remove the Audio Control Module (ACM) to retrieve the part number.
For additional information, refer to Audio Control Module (ACM) Self-Diagnostic Mode See:
Procedures/Audio Control Module (ACM) Self-Diagnostic Mode.
1. NOTE: Module configuration is required when a new ACM is being installed.
Upload the ACM configuration information to the scan tool.
2. Remove the instrument panel center finish panel.
3. Remove the 4 screws and the ACM.
- Disconnect the ACM electrical connectors.
4. To install, reverse the removal procedure.
- Download the configuration information to the ACM.
Accessory Protocol Interface Module (APIM)
Accessory Protocol Interface Module (APIM)
Floor Console Components
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Accessory Protocol Interface Module (APIM)
Removal and Installation
1. NOTE: It is necessary to record the current Accessory Protocol Interface Module (APIM)
software and hardware level when a new APIM is being
installed to make sure that the new component is the same version as the component being
replaced.
Retrieve and record the current APIM software and hardware level. For additional information, refer
to Accessory Protocol Interface Module (APIM) Software Level Check See: Procedures/Accessory
Protocol Interface Module (APIM) Software Level Check.
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Communications Control Module > Component Information > Service and Repair > Procedures > Page 63
2. Remove the 4 screws and the front floor console stowage door.
3. Remove the 2 screws and the front floor console rear trim panel.
- Pull straight back to disengage the clips.
4. Remove the 2 screws and the front floor console finish panel.
- Pull straight up to disengage the clips.
5. Remove the front floor console stowage bin.
- Remove the 4 screws.
- Disconnect the audio input jack electrical connector.
- Disconnect the Universal Serial Bus (USB) port electrical connector.
- Disconnect the APIM electrical connector.
- Disconnect the USB cable electrical connector (at the APIM).
6. Remove the 4 screws and the APIM.
7. To install, reverse the removal procedure.
- If a new APIM is being installed, program the APIM to the correct software level.
Universal Serial Bus (USB) Cable and Port
Universal Serial Bus (USB) Cable and Port
Floor Console Components
Universal Serial Bus (USB) Cable And Port-To-Bezel
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Communications Control Module > Component Information > Service and Repair > Procedures > Page 64
USB Cable And Port-To-Accessory Protocol Interface Module (APIM)
Removal and Installation
1. Remove the 4 screws and the front floor console stowage door.
2. Remove the 2 screws and the front floor console rear trim panel.
- Pull straight back to disengage the clips.
3. Remove the 2 screws and the front floor console finish panel.
- Pull straight up to disengage the clips.
4. Using a suitable tool (such as a trim removal tool) pry the audio input jack bezel from the storage
bin.
- Disconnect the audio input jack electrical connector.
5. Disconnect the Universal Serial Bus (USB) port connector from the audio input jack bezel.
6. Remove the 4 screws and the front floor console stowage bin.
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7. Remove the USB cable and port.
- Disconnect the electrical connector.
8. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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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Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 >
SYNC(R) System - Functions Inoperative/DTC's Set > Page 74
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 75
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 >
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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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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 82
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 83
^ 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 84
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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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 86
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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Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 87
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
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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 88
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 89
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 90
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 (V6-4.0L (2009))
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: > 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 > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-14-3 > Jul >
09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 96
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: > 09-14-3 > Jul >
09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 97
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 > All Technical Service Bulletins: > 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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09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 102
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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09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 103
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: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 104
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 (V6-4.0L (2009))
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Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 105
^ 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 (V6-4.0L (2009))
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: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 106
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 (V6-4.0L (2009))
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Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 107
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 (V6-4.0L (2009))
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Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 108
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 (V6-4.0L (2009))
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Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 109
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 (V6-4.0L (2009))
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: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 110
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 (V6-4.0L (2009))
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: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 111
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 (V6-4.0L (2009))
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Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 112
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 (V6-4.0L (2009))
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: > 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 (V6-4.0L (2009))
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: > 09-11-8 > Jun >
09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 117
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.
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Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-11-8 > Jun >
09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 118
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 (V6-4.0L (2009))
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: > 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 (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > 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 (V6-4.0L (2009))
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 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 (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Entertainment System Control Module > Component Information > Technical Service Bulletins > Page 142
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Entertainment System Control Module > Component Information > Technical Service Bulletins > Page 143
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 152
^ 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 (V6-4.0L (2009))
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 153
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 159
^ 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 (V6-4.0L (2009))
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 160
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 169
^ 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 (V6-4.0L (2009))
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 170
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 176
^ 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 (V6-4.0L (2009))
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 177
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 (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations
Parking Assist Control Module: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 181
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 182
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 183
Parking Assist Control Module: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 184
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 185
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 186
Parking Assist Control Module: Service and Repair
Parking Aid Module (PAM) - Explorer
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 bolts.
6. Remove the PAM assembly.
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 191
Memory Positioning Module: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 192
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 193
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 194
Memory Positioning Module: Service and Repair
Driver Seat Module (DSM)
Removal and Installation
NOTICE: 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 Driver Seat Module
(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: When a new DSM is installed, it is necessary to download the module configuration
information from the scan tool into the new DSM.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 195
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 201
Power Seat Relay: Locations Third Row Folding Seat Relay, Right
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 202
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay >
Component Information > Diagrams > Third Row Folding Seat Relay, Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 205
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 209
Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 210
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Locations > Page 215
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Locations > Page 216
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 (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Service and Repair
Seat Heater Control Module: Service and Repair
Seat - Exploded View, Front
Front Seat Backrest
NOTE: Driver backrest shown, passenger backrest similar.
Driver Seat Cushion
NOTE: Power seat track shown, manual seat track similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Service and Repair > Page 220
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Service and Repair > Page 221
Passenger Seat Cushion
NOTE: Manual seat track shown, power seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Service and Repair > Page 222
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Service and Repair > Page 223
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations
Sunroof / Moonroof Module: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations > Page 227
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations > Page 228
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay >
Component Information > Locations > Page 232
Trailer Towing Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay >
Component Information > Locations > Page 233
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations > Page 238
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations > Page 239
Electronic Brake Control Module: Diagrams
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations > Page 240
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations > Page 241
Electronic Brake Control Module: Service and Repair
Anti-Lock Brake System (ABS) Module
Removal and Installation
NOTICE: 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. See: Powertrain
Management/Computers and Control Systems/Information Bus/Testing and
Inspection/Programming and Relearning
1. Remove the Hydraulic Control Unit (HCU). For additional information, refer to Hydraulic Control
Unit (HCU) See: Brakes and Traction
Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock
Brakes/Service and Repair.
2. Remove the 4 screws and the ABS module.
- To install, tighten to 2 Nm (18 lb-in).
3. NOTICE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake
Control Module > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake
Control Module > Component Information > Locations > Page 245
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Auxiliary Blower Motor Relay
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Auxiliary Blower Motor Relay > Page 251
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Auxiliary Blower Motor Relay > Page 252
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Blower Motor Relay 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Blower Motor Relay 2 > Page 255
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Auxiliary Blower Motor Relay
Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 258
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 259
Blower Motor Relay: Testing and Inspection Blower Motor Relay 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 260
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 261
Blower Motor Relay: Testing and Inspection Blower Motor Relay 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 262
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 266
Compressor Clutch Relay: Description and Operation
Engine Control Components
Air Conditioning (A/C) Clutch Relay (A/CCR)
Note: The PCM parameter identifiers (PIDs) wide open throttle air conditioning cutoff (WAC) and
wide open throttle air conditioning cutoff fault (WAC_F) 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 and the engine conditions are OK (coolant temperature, engine RPM, throttle position),
the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to the A/CCR.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 267
Compressor Clutch Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 268
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Locations > Page 272
Control Module HVAC: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Locations > Page 273
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module
> Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 >
Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Fuel Distance/Mileage Module: Customer Interest Instruments - Trip Odometers/Fuel Economy
Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module
> Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 >
Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 283
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module:
> 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Fuel Distance/Mileage Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel
Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module:
> 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 289
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: >
09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Instrument Panel Control Module: Customer Interest Instruments - Trip Odometers/Fuel Economy
Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 298
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel
Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Instrument Panel Control Module: All Technical Service Bulletins Instruments - Trip
Odometers/Fuel Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 304
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 309
Fog/Driving Lamp Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 310
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > Page 317
Trailer Lighting Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Locations > Page 318
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
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> Component Information > Testing and Inspection > Page 323
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
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Component Information > Testing and Inspection > Page 327
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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)
Removal
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Distribution Module > Component Information > Service and Repair > Page 331
NOTICE: If the SJB is dropped, damage to the internal components may occur. A new SJB must
be installed.
NOTICE: 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.
NOTE: 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.
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. NOTICE: 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. 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 Remote Keyless Entry (RKE) transmitters may
be required to be present in order to program the RKE transmitters to the new SJB.
1. 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Module > Component Information > Service and Repair > Page 332
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 (177 lb-in).
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.
NOTE: 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.
Download the SJB configuration information from the scan tool into the new SJB. See: Accessories
and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry
Transmitter/Testing and Inspection/Remote Keyless Entry (RKE) Transmitter Programming
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.
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 DTC C2780.
Carry out the SJB self-test (must include an on-demand) by clearing DTCs, and then retrieving
DTCs to confirm all DTCs have been cleared.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations
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Distribution Relay > Component Information > Locations > Page 336
Power Distribution Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Distribution Relay > Component Information > Locations > Page 337
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Distribution Relay > Component Information > Locations > Page 338
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Battery Junction Box (BJB)
Relay Box: Locations Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Locations > Battery Junction Box (BJB) > Page 343
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Locations > Battery Junction Box (BJB) > Page 344
Relay Box: Locations Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Locations > Battery Junction Box (BJB) > Page 345
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Locations > Battery Junction Box (BJB) > Page 346
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Locations > Battery Junction Box (BJB) > Page 347
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Locations > Battery Junction Box (BJB) > Page 348
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Locations > Battery Junction Box (BJB) > Page 349
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Diagrams > Battery Junction Box (BJB) > Page 352
Relay Box: Diagrams Smart Junction Box (SJB)
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Component Information > Diagrams > Battery Junction Box (BJB) > Page 353
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Diagrams > Battery Junction Box (BJB) > Page 354
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Diagrams > Battery Junction Box (BJB) > Page 355
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Battery Junction Box (BJB) > Page 356
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Battery Junction Box (BJB) > Page 357
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Application and ID > Battery Junction Box (BJB)
Relay Box: Application and ID Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Application and ID > Battery Junction Box (BJB) > Page 360
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Battery Junction Box (BJB) > Page 361
Relay Box: Application and ID Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Application and ID > Battery Junction Box (BJB) > Page 362
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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), which delivers 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 torque-based 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 two 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. 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 one reference voltage and one signal return circuit between the PCM and the ETB. The
reference voltage and the signal return circuits are shared with the reference voltage and signal
return circuits used by the accelerator pedal position (APP) sensor. There are also two throttle
position (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. For additional
information on the APP sensor, refer to Engine Control Components See: Powertrain
Management/Computers and Control Systems/Description and Operation/Engine Control
Components.
Electronic Throttle Control (ETC) System Strategy
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)
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Operation > Page 368
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 two 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.
ETC System With A 3-Track APP Sensor Failure Mode And Effects Management:
a - ETC illuminates or displays a message on the message center immediately; MIL illuminates
after 2 driving cycles
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Operation > Page 369
ETC System With A 2-Track APP Sensor Failure Mode And Effects Management:
Electronic Throttle Monitor Operation:
a - Monitor execution is continuous. Monitor false detection duration is less than 1 second to
register a concern.
APP and TP Sensor Inputs
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Operation > Page 370
Accelerator Pedal Position (APP) Sensor Check:
Correlation and range/performance - sensor disagreement between processors internal to the
PCM. Monitor execution is continuous. Monitor false detection duration is less than 1 second to
register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions for additional
DTC information.
Throttle Position (TP) Sensor Check:
a - Correlation and range/performance - sensor disagreement between processors internal to the
PCM, TP inconsistent with requested throttle plate position. Monitor execution is continuous.
Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic
Trouble Code (DTC) Charts and Descriptions for additional DTC information.
Electronic Throttle Actuator Control (TAC) Output
Electronic TAC Operation Check:
a - Note: For all DTCs, in addition to the MIL, the powertrain malfunction indicator (wrench) is on for
the concern that caused the FMEM action. Monitor execution is continuous. Monitor false detection
duration is less than 5 seconds to register a concern.
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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 > Technical Service Bulletins >
Customer Interest for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2
Shift
Engine Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
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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 > Technical Service Bulletins >
Customer Interest for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2
Shift > Page 379
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2
Shift > Page 380
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
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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 > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift
Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
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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 > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift > Page 386
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
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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 > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift > Page 387
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
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Engine Control Module: Locations
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391
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392
Engine Control Module: Diagrams
C175B Part 1
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C175B Part 2
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394
C175E Part 1
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C175E Part 2
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396
C175E Part 3
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397
C175T Part 1
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C175T Part 2
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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 > 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 DTC P1635 or
P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware
or parameter changes made to the vehicle since production. Failure to carry out this procedure
properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle
ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID
Block and also under Making Changes to the PCM Calibration. The VID block contains many items
used by the strategy for a variety of functions. Some of these items include the vehicle identification
number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the
presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual
shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID
block is displayed on the scan tool.
When changing items in the VID block, the strategy places range limits on certain items such as
tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this
limit is reached, the scan tool displays a message indicating the need to flash the PCM again to
reset the VID block.
On selected vehicles equipped with permanent DTC reporting capabilities, neutral profile correction
should be learned after a PCM replacement in order to activate the misfire monitor. This can be
accomplished using the Misfire Monitor Neutral Profile Learn function on the scan tool.
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.
Neutral Profile Correction
In order for the misfire detection system to function properly, any mechanical inaccuracies in the
crankshaft position (CKP) sensor must be learned by the PCM. This information is stored in
non-volatile memory (NVM) in the PCM. It is not cleared when the keep alive memory (KAM) is
reset.
Neutral profile learning is accomplished using the scan tool any time a PCM is replaced. It should
also be relearned any time the CKP sensor is replaced or major engine repairs have been
completed.
To determine if the neutral profile learning has been completed, check the MP_LRN parameter
identification (PID) using the scan tool. The PID should read YES if the neutral profile learning has
been completed. If the PID reads NO, complete the neutral profile learning prior to diagnosing any
misfire DTCs.
Programming the VID Block for a Replacement PCM
The VID block on a replacement PCM is blank and requires programming. There are two
procedures available. The first is an automatic data transfer from the old PCM to the new PCM,
and the second is manual data entry into the new PCM.
Automatic data transfer 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 be downloaded to the new PCM after it has been installed.
Carry out manual data entry if the old PCM 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 programmed PCM 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
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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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Page 402
Engine Control Module: Removal and Replacement
Powertrain Control Module (PCM)
A/C Tube Brackets
PCM
Removal
All vehicles
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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 (PMI) procedure. See: Powertrain Management/Computers and
Control Systems/Information Bus/Testing and Inspection/Programming and Relearning
Vehicles equipped with a 4.6L (3V) engine
2. Remove the Air Cleaner (ACL).
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 2 bolts and the PCM.
Installation
All vehicles
1. Install the PCM and the 2 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.
- Tighten to 7 Nm (62 lb-in).
Vehicles equipped with a 4.6L (3V) engine
4. Install the ACL.
All vehicles
5. Restore the module configuration. Carry out the module configuration restore steps of the
Programmable Module Installation (PMI) procedure.
See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and
Inspection/Programming and Relearning
6. Reprogram the Passive Anti-Theft System (PATS). Carry out the Parameter Reset procedure.
See: Accessories and Optional Equipment/Antitheft
and Alarm Systems/Testing and Inspection/Programming and Relearning/Passive Anti-Theft
System (PATS) Parameter Reset
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Main Relay (Computer/Fuel System): Testing and Inspection
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > EGR Control Module > Component Information > Locations
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> Page 419
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Fuel Pump Control Unit: Service and Repair
Fuel Pump Driver Module (FPDM) - Explorer, Mountaineer
Removal and Installation
1. Remove the RH rear quarter trim panel.
2. Disconnect the Fuel Pump Driver Module (FPDM) electrical connector.
3. Remove the 2 bolts and the FPDM.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
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Fuel Pump Relay: Testing and Inspection
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Main Relay (Computer/Fuel System): Testing and Inspection
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations
Air Bag Control Module: Locations
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Component Information > Locations > Page 437
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Component Information > Diagrams > Driver Can Vent Unit
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Component Information > Diagrams > Driver Can Vent Unit > Page 440
Air Bag Control Module: Diagrams Restraints Control Module (RCM)
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Part 1
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Component Information > Diagrams > Driver Can Vent Unit > Page 442
Part 2
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Component Information > Diagrams > Page 443
Air Bag Control Module: Service and Repair
Restraints Control Module (RCM)
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(R) and
cause serious personal injury or death.
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.
NOTICE: When installing a new Restraints Control Module (RCM), it is necessary to carry out
Programmable Module Installation (PMI). Failure to follow these instructions may result in
component damage and/or system failure. See: Powertrain Management/Computers and Control
Systems/Information Bus/Testing and Inspection/Programming and Relearning
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.
NOTE: The air bag warning indicator illuminates when the correct RCM fuse is removed and the
ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. If installing a new RCM, carry out the steps necessary to prepare for Programmable Module
Installation (PMI). See: Powertrain
Management/Computers and Control Systems/Information Bus/Testing and
Inspection/Programming and Relearning
2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and
Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering
in the General Procedures.
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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 (106 lb-in).
3. Connect the small RCM electrical connector.
4. NOTE: The RCM has been removed for clarity.
On the large RCM electrical connector, place the connector position assurance lever in the full
release position.
5. NOTICE: Putting the large electrical connector into the Restraints Control Module (RCM) on an
angle may cause bad electrical
connections and damage components.
Position the large electrical connector into the RCM.
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6. Connect the large RCM connector.
- NOTICE: 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 electrical connector uniformly aligned to the RCM, lightly push in until a subtle
audible click is heard and a slight resistance is felt.
- Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into
the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.
7. Install the front floor console.
8. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to
Supplemental Restraint System (SRS) Depowering
and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS)
Depowering and Repowering in the General Procedures.
9. When installing a new RCM, carry out the steps necessary to complete Programmable Module
Installation (PMI). See: Powertrain
Management/Computers and Control Systems/Information Bus/Testing and
Inspection/Programming and Relearning
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 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 an 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.
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Module - Air Bag > Component Information > Locations
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Module - Air Bag > Component Information > Locations > Page 449
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Module - Air Bag > Component Information > Locations > Page 450
Seat Occupant Classification Module - Air Bag: Service and Repair
Occupant Classification System Module (OCSM)
NOTE: Power seat shown, manual seat similar.
Removal
NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and
Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering
in the General Procedures.
2. Disconnect the Occupant Classification System Module (OCSM) electrical connector underneath
the front of the passenger seat.
3. NOTE: Note the position of the locator tab on the OCSM for installation.
Remove the 2 screws and the OCSM.
4. To install, reverse the removal procedure.
5. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to
Supplemental Restraint System (SRS) Depowering
and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS)
Depowering and Repowering in the General Procedures.
6. Carry out the appropriate procedure after installation of an Occupant Classification Sensor
(OCS) system component.
- If installing the original OCS system component, carry out the OCS System Zero Seat Weight
Test and prove out the SRS. For additional information, refer to Occupant Classification Sensor
(OCS) System Zero Seat Weight Test See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Component Tests and General Diagnostics.
- If installing a new OCS system component, carry out the OCS Reset and prove out the SRS. For
additional information, refer to Occupant Classification Sensor (OCS) System Reset See: Restraint
Systems/Air Bag Systems/Service and Repair/Occupant Classification Sensor (OCS) System
Reset.
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Component Information > Locations > Starter Relay
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Component Information > Locations > Starter Relay > Page 456
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Component Information > Testing and Inspection > Starter Relay
Starter Relay: Testing and Inspection Starter Relay
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Component Information > Testing and Inspection > Starter Relay > Page 459
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Component Information > Testing and Inspection > Starter Relay > Page 460
Starter Relay: Testing and Inspection Run/Start Relay
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Component Information > Testing and Inspection > Starter Relay > Page 461
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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:
> 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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:
> 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 472
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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:
> 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 473
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2
Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 479
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 480
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Page 485
Heated Glass Element Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Page 486
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Locations > Page 491
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Page 495
Wiper Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Page 496
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left
Parking Assist Distance Sensor: Locations Parking Aid Sensor, Outer Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 503
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 504
Parking Assist Distance Sensor: Locations Parking Aid Sensor, Outer Right
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 505
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 506
Parking Assist Distance Sensor: Locations Parking Aid Sensor, Inner Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 507
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 508
Parking Assist Distance Sensor: Locations Parking Aid Sensor, Inner Right
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 509
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 512
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 513
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 514
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal
Positioning Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal
Positioning Switch > Component Information > Locations > Page 518
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote
Switch, Audio - Stereo > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote
Switch, Audio - Stereo > Component Information > Locations > Page 522
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Locations > Page 527
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Door Lock Switch, Passenger Side
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 532
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Door Lock Switch, Driver Side
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 535
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 536
Power Door Lock Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 537
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 538
Power Door Lock Switch: Service and Repair
Door Lock Control Switch
Removal and Installation
NOTE: The LH side is shown, the RH side is similar.
1. Remove the interior door handle cover.
2. Remove the front door switch bezel.
- Release the 4 retaining tabs.
3. Disconnect the door lock control switch and window control switch electrical connectors.
4. Remove the door lock control switch.
- Release the 4 retaining tabs.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 542
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 543
Power Mirror Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 544
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 545
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 546
Power Mirror Switch: Service and Repair
Exterior Mirror Control Switch
Removal and Installation
1. Remove the front door trim panel.
2. Depress the 2 retaining tabs and remove the exterior mirror control switch from the front door
trim panel.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Third Row Folding Seat Switch, Left
Power Seat Switch: Locations Third Row Folding Seat Switch, Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Third Row Folding Seat Switch, Left > Page 551
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Third Row Folding Seat Switch, Left > Page 552
Power Seat Switch: Locations Third Row Folding Seat Switch, Right
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Third Row Folding Seat Switch, Left > Page 553
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Third Row Folding Seat Switch, Left > Page 554
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Third Row Folding Seat Switch, Left > Page 555
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams > Power Seat Switch, Left
Power Seat Switch: Diagrams Power Seat Switch, Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams > Power Seat Switch, Left > Page 558
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams > Power Seat Switch, Left > Page 559
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams > Power Seat Switch, Left > Page 560
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams > Power Seat Switch, Left > Page 561
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat
Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 6-Way Power Seat
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 564
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 565
Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 10-Way Power Seat
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 566
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 567
Power Seat Switch: Testing and Inspection Power Seat Switch, Right
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 568
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat - Exploded View, Front
Power Seat Switch: Service and Repair Seat - Exploded View, Front
Seat - Exploded View, Front
Front Seat Backrest
NOTE: Driver backrest shown, passenger backrest similar.
Driver Seat Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat - Exploded View, Front > Page 571
NOTE: Power seat track shown, manual seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat - Exploded View, Front > Page 572
Passenger Seat Cushion
NOTE: Manual seat track shown, power seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat - Exploded View, Front > Page 573
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat - Exploded View, Front > Page 574
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat - Exploded View, Front > Page 575
Power Seat Switch: Service and Repair Memory Set Switch
Memory Set Switch
Removal and Installation
1. Position the gear selector to NEUTRAL.
2. Remove the console trim ring.
3. Open the center console door, remove the 2 screws and pull up on the console finish panel to
release the retainers.
4. Disconnect the power point electrical connector and remove the console finish panel.
5. Pull out to release the retainers and separate the instrument panel center lower RH and LH
finish panels.
6. Pull out to release the retainers and separate the instrument panel center finish panel.
7. Disconnect the electrical connector, release the 4 tabs and remove the memory SET switch.
8. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat - Exploded View, Front > Page 576
Power Seat Switch: Service and Repair Seat Control Switch
Seat Control Switch
Removal and Installation
All seats
1. Remove the front seat. For additional information, refer to Seat - Front See: Body and
Frame/Seats/Service and Repair/Front Seats/Seat - Front.
2. Remove the cushion side shield in the following sequence.
1. Remove the clip and manual recline handle (if equipped).
2. Pull and remove the manual lumbar control knob (if equipped).
3. Remove the scrivet.
4. Remove the retention bracket screw and the retention bracket (if equipped).
5. Release the cushion side shield front clip.
6. From under the cushion side shield, release the 3 hook retainers.
7. Pull out on the cushion side shield at the back and release the pin-type retainer.
8. Separate the cushion trim cover elastic strap from the cushion side shield.
9. 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. For additional information, refer to Seat Front See: Body and Frame/Seats/Service and Repair/Front Seats/Seat - Front.
Passenger seat
6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS. For additional information, refer to
General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing
and Inspection/Component Tests and General Diagnostics
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat - Exploded View, Front > Page 577
Power Seat Switch: Service and Repair Seat Control Switch - Third Row
Seat Control Switch - Third Row
Removal and Installation
NOTE: The third row seat control switches are located in the LH quarter trim panel.
1. Pull out on the third row seat control switch bezel and separate from the LH quarter trim panel.
2. Disconnect the third row seat control switch(es), release the retainers and remove the third row
seat control switch(es).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Sliding Door Switch
> Component Information > Locations
Power Sliding Door Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Sliding Door Switch
> Component Information > Locations > Page 581
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Sliding Door Switch
> Component Information > Locations > Page 582
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Sliding Door Switch
> Component Information > Locations > Page 583
Power Sliding Door Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Sliding Door Switch
> Component Information > Locations > Page 584
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Page 588
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Page 589
Power Trunk / Liftgate Lock Switch: Service and Repair
Liftgate Window Latch Actuator
Removal and Installation
1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See:
Body and Frame/Doors, Hood and
Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/Liftgate Window Latch.
2. Remove the 3 screws and the liftgate window latch actuator.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Locations > Page 593
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch
Seat Heater Switch: Service and Repair Heated Seat Switch
Heated Seat Switch
Removal and Installation
1. Position the gear selector to NEUTRAL.
2. Remove the console trim ring.
3. Open the center console door, remove the 2 screws and pull up on the console finish panel to
release the retainers.
4. Disconnect the power point electrical connector and remove the console finish panel.
5. Pull out to release the retainers and separate the instrument panel center lower RH and LH
finish panels.
6. Pull out to release the retainers and separate the instrument panel center finish panel.
7. Disconnect the electrical connector, release the 4 tabs and remove the heated seat/heated
windshield switch pack.
8. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 - Exploded View, Front
Seat - Exploded View, Front
Front Seat Backrest
NOTE: Driver backrest shown, passenger backrest similar.
Driver Seat Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
NOTE: Power seat track shown, manual seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Passenger Seat Cushion
NOTE: Manual seat track shown, power seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Locations > Page 604
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch
> Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch
> Component Information > Locations > Page 611
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor
Block > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor
Block > Component Information > Locations > Page 616
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Service and Repair
Acceleration/Deceleration Sensor: Service and Repair
Stability Control Sensor Cluster
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 620
- To install, tighten to 7 Nm (62 lb-in).
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster
Vacuum Sensor > Component Information > Locations > Page 624
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster
Vacuum Sensor > Component Information > Locations > Page 625
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 629
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 630
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Warning Switch > Component Information > Locations > Page 634
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Warning Switch > Component Information > Locations > Page 635
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 screws and the steering wheel rotation sensor.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control
Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control
Switch > Component Information > Locations > Page 642
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control
Switch > Component Information > Locations > Page 643
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.
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 (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 648
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 649
Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 650
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 651
Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Rear
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 652
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 653
Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Rear
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 654
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 657
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 658
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 659
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
- To install, tighten to 8 Nm (71 lb-in).
4. Remove the wheel speed sensor harness pin-type retainers.
5. Remove the wheel speed sensor bolt and the wheel speed sensor.
- To install, tighten the bolt to 17 Nm (150 lb-in).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 662
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.
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 (V6-4.0L (2009))
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 663
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring - Rear
Wheel Speed Sensor Ring - Rear
Removal
1. Remove the rear halfshaft.
2. Using a suitable driver, remove the ABS wheel speed sensor ring.
Installation
1. Install the new ABS wheel speed sensor and the Wheel Speed Sensor Ring Installers on the
halfshaft as shown.
2. Using the Wheel Speed Sensor Ring Installers, install the ABS wheel speed sensor ring as
shown.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 664
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
Fan Speed Sensor (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. For additional information on the cooling fan clutch, refer to the Cooling Fan Clutch.
Cooling Fan Clutch with Fan Speed Sensor (FSS)
Cooling Fan Clutch with FSS
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Page 673
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Page 674
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Engine Control Components
Engine Coolant Temperature (ECT) Sensor
The ECT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases, and the resistance
increases as the temperature decreases. The varying resistance changes the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor
determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage
minus the voltage drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The PCM uses the ECT input for fuel
control and for cooling fan control. There are three types of ECT sensors, threaded, push-in, and
twist-lock. The ECT sensor is located in an engine coolant passage.
Typical Thread Type Sensor
Typical Thread Type ECT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Page 675
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature (ECT) Sensor - 4.0L SOHC
Removal and Installation
1. Drain the cooling system.
2. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
3. Remove the clip and the ECT sensor.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 679
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 680
Engine Temperature Sensor: Description and Operation
Engine Control Components
Cylinder Head Temperature (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. For
additional information, refer to Powertrain Control Software See: Powertrain
Management/Computers and Control Systems/Description and Operation/Powertrain Control
Software for Fail-Safe Cooling Strategy.
Typical CHT Sensor
Typical CHT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Locations
Brake Switch (Cruise Control): Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Locations > Page 685
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Locations > Page 686
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Description and Operation > Brake Pedal Position (BPP) Switch
Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch
Engine Control Components
Brake Pedal Position (BPP) Switch
The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal
to the PCM indicating the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Typical BPP Switch
Typical BPP Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 689
Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS)/Brake
Deactivator Switch
Engine Control Components
Brake Pedal Switch (BPS)/Brake Deactivator Switch
The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A
normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is
not applied. When the brake pedal is applied, the normally closed switch opens and power is
removed from the PCM.
On some applications the normally closed BPS, along with the normally open BPP switch, are used
for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be
disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not
changing states when they were expected to, a diagnostic trouble code (DTC) is set by the PCM
strategy.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
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.
Typical Clutch Pedal Position (CPP) Switch
Typical Clutch Pedal Position (CPP) Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Service and Repair
Cruise Control Switch: Service and Repair
Speed Control Switch
NOTE: Explorer shown, Mountaineer similar.
Removal and Installation
NOTE: It is not necessary to remove the driver air bag module during this procedure.
NOTE: Be careful not to allow the speed control switch electrical connector to fall back into the
steering wheel.
1. Remove the speed control switch by pulling the switch toward the rear of the vehicle.
- Disconnect the electrical connector.
2. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations
Oil Pressure Sender: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations > Page 700
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations > Page 701
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 Control Components
Engine Oil Temperature (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.
Typical Thread Type Sensor
Typical EOT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 709
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 710
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 711
Ambient Temperature Sensor / Switch HVAC: Testing and Inspection
Climate Control System
Component Tests
Temperature Sensor - Ambient
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Locations > Page 715
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Locations > Page 716
Blower Motor Switch: Service and Repair
Blower Motor Speed Control
Removal and Installation
1. Remove the blower motor speed control screw.
2. Remove the blower motor speed control.
3. Disconnect the blower motor speed control electrical connector.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations > Page 720
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations > Page 721
Cabin Temperature Sensor / Switch: Testing and Inspection
Climate Control System
Component Tests
Temperature Sensor - In-Vehicle
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Service and Repair > Ambient Air Temperature Sensor
Cabin Temperature Sensor / Switch: Service and Repair Ambient Air Temperature Sensor
Ambient Air Temperature Sensor
Removal and Installation
Mountaineer
1. Remove the radiator grille.
2. Remove the pin-type retainers and position the air deflector forward.
3. Remove the 2 air deflector pin-type retainers and detach the air deflector from the 2 locator pins
on the radiator support.
All vehicles
4. Detach the ambient air temperature sensor electrical connector.
5. Remove the ambient air temperature sensor.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Service and Repair > Ambient Air Temperature Sensor > Page 724
Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor
In-Vehicle Temperature Sensor
Removal and Installation
1. Remove the instrument cluster finish panel.
2. Remove the in-vehicle temperature sensor.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
Air Conditioning Evaporator Temperature (ACET) Sensor
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 and improve defrost/demist
performance.
Note: These values can vary 15% due to sensor and VREF variations. Voltage values were
calculated for VREF equals 5.0 volts.
A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Locations
Refrigerant Pressure Sensor / Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Locations > Page 731
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Diagrams > A/C Cycling Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Diagrams > A/C Cycling Switch > Page 734
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Description and Operation > Air Conditioning (A/C) Cycling Switch
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Cycling
Switch
Engine Control Components
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 the Climate Control System Air Conditioning System Overview.
Also, refer to the applicable Wiring Diagrams for vehicle specific wiring.
If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate.
For additional information, refer to wide open throttle air conditioning cutoff (WAC).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Description and Operation > Air Conditioning (A/C) Cycling Switch > Page 737
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) High
Pressure Switch
Engine Control Components
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 for 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 the Climate Control System, Air Conditioning System Overview
or the Wiring Diagrams.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Description and Operation > Air Conditioning (A/C) Cycling Switch > Page 738
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Pressure (ACP)
Transducer Sensor
Engine Control Components
Air Conditioning Pressure (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.
A/C Pressure Transducer Sensor Output Voltage Vs Pressure Chart
Typical ACP Transducer Sensor
Typical ACP Transducer Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Locations > Page 742
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal and Installation
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.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front > Page 751
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front > Page 752
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front > Page 753
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front > Page 754
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch > Page 757
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch > Page 758
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch > Page 759
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch > Page 760
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal and Installation
1. Remove the front door latch. For additional information, refer to Front Door Latch See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Front Door Latch/Service and Repair/Removal and Replacement/Front Door Latch.
2. Disconnect the front door ajar switch electrical connector.
3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the
switch from the front door latch.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 763
Door Switch: Service and Repair Door Ajar Switch - Liftgate
Door Ajar Switch - Liftgate
Removal and Installation
1. Remove the liftgate latch. For additional information, refer to Liftgate Latch See: Body and
Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk
/ Liftgate Latch/Service and Repair/Liftgate Latch.
2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar
switch form the liftgate latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 764
Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass
Door Ajar Switch - Liftgate Glass
Removal and Installation
1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See:
Body and Frame/Doors, Hood and
Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/Liftgate Window Latch.
2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the
liftgate window latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 765
Door Switch: Service and Repair Door Ajar Switch - Rear Door
Door Ajar Switch - Rear Door
Removal and Installation
1. Remove the rear door latch. For additional information, refer to Rear Door Latch See: Body and
Frame/Doors, Hood and Trunk/Doors/Rear
Door/Rear Door Latch/Service and Repair/Removal and Replacement/Rear Door Latch.
2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch
from the rear door latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams
Fuel Gauge Sender: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Fuel Pump (FP) Module
Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module
Engine Control Components
Fuel Pump (FP) Module
The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is
located inside the FP module reservoir and supplies fuel through the FP module manifold to the
engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a
check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Mechanical Returnless Fuel Pump (FP) Module
Typical Mechanical Returnless Fuel Pump (FP) Module
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Fuel Pump (FP) Module > Page 771
Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module and Reservoir
Engine Control Components
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 ignition has been turned off to minimize starting
concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low
tank fill levels.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Page 772
Fuel Gauge Sender: Service and Repair
Fuel Tank and Filler Pipe - Exploded View
Explorer Sport Trac
NOTE: Vehicle body removed from art for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Page 773
Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Page 774
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Page 775
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Locations > Page 779
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Locations > Page 780
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 785
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 786
Ambient Light Sensor: Service and Repair
Light Sensor
Removal and Installation
1. Position the top portion of the lower center instrument panel finish panel rearward.
2. Remove the upper center instrument panel finish panel.
- Disconnect the electrical connector.
3. Remove the 2 screws and the light sensor.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations
Backup Lamp Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Page 790
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Page 791
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
Brake Light Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 795
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 796
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 797
Brake Light Switch: Description and Operation
Engine Control Components
Brake Pedal Position (BPP) Switch
The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal
to the PCM indicating the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Typical BPP Switch
Typical BPP Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 798
Brake Light Switch: Service and Repair
Stoplamp Switch
Removal and Installation
NOTICE: Do not remove or repair the brake pedal, brake booster or master cylinder without first
removing the stoplamp switch. Do not install the stoplamp switch without the brake pedal arm
secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or
installing the stoplamp switch, as misadjustment or damage to the switch may occur.
1. Disconnect the stoplamp switch electrical connector.
2. Rotate the stoplamp switch 45 degrees clockwise and remove the stoplamp switch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Door Ajar Switch, Driver Side Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 803
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 804
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 805
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 806
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Liftgate Glass Ajar Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 809
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 810
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 811
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 812
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal and Installation
1. Remove the front door latch. For additional information, refer to Front Door Latch See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Front Door Latch/Service and Repair/Removal and Replacement/Front Door Latch.
2. Disconnect the front door ajar switch electrical connector.
3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the
switch from the front door latch.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 815
Door Switch: Service and Repair Door Ajar Switch - Liftgate
Door Ajar Switch - Liftgate
Removal and Installation
1. Remove the liftgate latch. For additional information, refer to Liftgate Latch See: Body and
Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk
/ Liftgate Latch/Service and Repair/Liftgate Latch.
2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar
switch form the liftgate latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 816
Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass
Door Ajar Switch - Liftgate Glass
Removal and Installation
1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See:
Body and Frame/Doors, Hood and
Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/Liftgate Window Latch.
2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the
liftgate window latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 817
Door Switch: Service and Repair Door Ajar Switch - Rear Door
Door Ajar Switch - Rear Door
Removal and Installation
1. Remove the rear door latch. For additional information, refer to Rear Door Latch See: Body and
Frame/Doors, Hood and Trunk/Doors/Rear
Door/Rear Door Latch/Service and Repair/Removal and Replacement/Rear Door Latch.
2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch
from the rear door latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations > Illumination Dimmer Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations > Illumination Dimmer Switch > Page 822
Headlamp Dimmer Switch: Locations Multifunction Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations > Illumination Dimmer Switch > Page 823
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Multifunction Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Multifunction Switch > Page 826
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch
Headlamp Dimmer Switch: Testing and Inspection Illumination Dimmer Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 829
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 830
Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 831
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Testing and Inspection > Page 832
Headlamp Dimmer Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Removal and Installation
NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Remove the 2 screws and the steering column opening cover.
2. Remove the 3 screws and the upper and lower steering column shrouds.
3. Disconnect the multifunction switch electrical connector.
4. Remove the 2 multifunction switch screws and the multifunction switch.
- To install, tighten to 3 Nm (27 lb-in).
5. To install, reverse the removal procedure.
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Component Information > Locations
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Component Information > Locations > Page 836
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 837
Headlamp Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 838
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 839
Headlamp Switch: Service and Repair
Headlamp Switch
Removal and Installation
1. Remove the driver side register.
2. Remove the headlamp switch and bezel as an assembly.
- Disconnect the electrical connectors.
3. Remove the 3 screws and the headlamp switch.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
Turn Signal Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 846
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 847
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 848
Turn Signal Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 849
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 850
Turn Signal Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Removal and Installation
NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Remove the 2 screws and the steering column opening cover.
2. Remove the 3 screws and the upper and lower steering column shrouds.
3. Disconnect the multifunction switch electrical connector.
4. Remove the 2 multifunction switch screws and the multifunction switch.
- To install, tighten to 3 Nm (27 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 856
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 857
Accelerator Pedal Position Sensor: Description and Operation
Engine Control Components
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
There are two 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 two
pedal position signals make sure the PCM receives a correct input even if one 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 two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six
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 (TP) 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. For additional information, refer
to Torque Based Electronic Throttle Control (ETC) See: Powertrain Management/Computers and
Control Systems/Electronic Throttle Control Module/Description and Operation.
2-Track APP Sensor
Typical 2-Track APP Sensor
3-Track APP Sensor
There are three 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 three pedal position signals make sure the PCM
receives a correct input even if one 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 two reference voltage circuits, two signal
return circuits, and three signal circuits (a total of seven 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. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) See: Powertrain Management/Computers and Control Systems/Electronic Throttle
Control Module/Description and Operation.
3-Track APP Sensor
Typical 3-Track APP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
Air Flow Meter/Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 861
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 862
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 863
Air Flow Meter/Sensor: Description and Operation
Engine Control Components
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 (TCC) 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 IAT sensor.
The hot wire electronic sensing element must be replaced as an assembly. Replacing only the
element may change the air flow calibration.
Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT
Sensor Wire Where Applicable) Terminals
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
Typical Mass Air Flow (MAF) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 864
Typical Drop-in Mass Air Flow (MAF) Sensor
Typical Drop-in Mass Air Flow (MAF) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 865
Air Flow Meter/Sensor: Service and Repair
Mass Air Flow (MAF) Sensor - 4.0L SOHC
Removal and Installation
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the 2 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 (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft
Position Sensor 1
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft
Position Sensor 1 > Page 870
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft
Position Sensor 1 > Page 871
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft
Position Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft
Position Sensor > Page 874
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft
Position Sensor > Page 875
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 876
Camshaft Position Sensor: Description and Operation
Engine Control Components
Camshaft Position (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 two CMP sensors are equipped with variable camshaft timing (VCT). The second
sensor is used to identify the position of the camshaft on bank 2.
There are two types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin
Hall-effect type sensor.
Typical Variable Reluctance CMP Sensor
Typical Variable Reluctance CMP Sensor
Typical Hall-effect CMP Sensor
Typical Hall-effect CMP Sensor
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 877
Camshaft Position Sensor: Service and Repair
Camshaft Position (CMP) Sensor - 4.0L SOHC
Removal and Installation
1. Disconnect the Camshaft Position (CMP) sensor electrical connector.
2. Remove the bolt and the CMP sensor.
- To install, tighten to 6 Nm (53 lb-in).
3. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation
Clutch Switch: Description and Operation
Engine Control Components
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.
Typical Clutch Pedal Position (CPP) Switch
Typical Clutch Pedal Position (CPP) Switch
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 884
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 885
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Engine Control Components
Engine Coolant Temperature (ECT) Sensor
The ECT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases, and the resistance
increases as the temperature decreases. The varying resistance changes the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor
determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage
minus the voltage drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The PCM uses the ECT input for fuel
control and for cooling fan control. There are three types of ECT sensors, threaded, push-in, and
twist-lock. The ECT sensor is located in an engine coolant passage.
Typical Thread Type Sensor
Typical Thread Type ECT Sensor
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 886
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature (ECT) Sensor - 4.0L SOHC
Removal and Installation
1. Drain the cooling system.
2. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
3. Remove the clip and the ECT sensor.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
890
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
891
Crankshaft Position Sensor: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
892
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
893
Crankshaft Position Sensor: Description and Operation
Engine Control Components
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.
Typical Crankshaft Position (CKP) Sensor
Typical Crankshaft Position (CKP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
894
Crankshaft Position Sensor: Service and Repair
Crankshaft Position (CKP) Sensor - 4.0L SOHC
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
3. Remove the 2 bolts and the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. NOTE: Be sure the sensor wiring is routed away from the battery cable.
To install, reverse the removal procedure.
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Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations
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Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page
898
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page
899
Engine Temperature Sensor: Description and Operation
Engine Control Components
Cylinder Head Temperature (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. For
additional information, refer to Powertrain Control Software See: Powertrain
Management/Computers and Control Systems/Description and Operation/Powertrain Control
Software for Fail-Safe Cooling Strategy.
Typical CHT Sensor
Typical CHT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation
Fuel Level Sensor: Description and Operation
Engine Control Components
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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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel
Tank and Filler Pipe - Exploded View
Fuel Level Sensor: Service and Repair Fuel Tank and Filler Pipe - Exploded View
Fuel Tank and Filler Pipe - Exploded View
Explorer Sport Trac
NOTE: Vehicle body removed from art for clarity.
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel
Tank and Filler Pipe - Exploded View > Page 905
Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel
Tank and Filler Pipe - Exploded View > Page 907
1. For additional information, refer to the procedures.
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel
Tank and Filler Pipe - Exploded View > Page 908
Fuel Level Sensor: Service and Repair Fuel Level Sender
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 (FP). For additional information, refer to Fuel Pump See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel
Pump/Service and Repair/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.
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.
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel
Tank and Filler Pipe - Exploded View > Page 909
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 FP body.
2. Route the fuel level sender wire through the center of the FP.
3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate.
Hook the fuel level sender on the FP 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.
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel
Tank and Filler Pipe - Exploded View > Page 910
6. Install the fuel level sender cover and screw and tighten the screw.
7. Install the FP. For additional information, refer to Fuel Pump See: Powertrain Management/Fuel
Delivery and Air Induction/Fuel Pump/Service
and Repair/Fuel Pump.
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Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations
Fuel Tank Pressure Sensor: Locations
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Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page
914
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Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page
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Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page
916
Fuel Tank Pressure Sensor: Description and Operation
Engine Control Components
Fuel Tank Pressure (FTP) Sensor
The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure.
Fuel Tank Pressure (FTP) Sensor
Fuel Tank Pressure (FTP) Sensor
In-line Fuel Tank Pressure (FTP) Sensor
In-line Fuel Tank Pressure (FTP) Sensor
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917
Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor
Removal and Installation
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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: 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. For additional information, refer to
Evaporative Emission Canister See: Powertrain
Management/Emission Control Systems/Evaporative Emissions System/Evaporative Emission
Control Canister/Service and Repair.
2. Remove the fuel tank shield from the fuel tank.
3. Disconnect the Fuel Tank Pressure (FTP) sensor electrical connector.
4. Disconnect the 3 FTP sensor and vapor tube assembly quick connect couplings from the Fuel
Pump (FP) module and the vapor vent valves.
5. Remove the FTP sensor and vapor tube assembly.
6. To install, reverse the removal procedure.
- Carry out the Evaporative Emission System Leak Test. For additional information, refer to
Evaporative Emission System Leak Test See: Powertrain Management/Emission Control
Systems/Evaporative Emissions System/Testing and Inspection.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
Intake Air Temperature Sensor: Locations
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Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
921
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Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
922
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Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
923
Intake Air Temperature Sensor: Description and Operation
Engine Control Components
Intake Air Temperature (IAT) 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 sensor provides air temperature information to the PCM. The PCM uses the air
temperature information as a correction factor in the calculation of fuel, spark, and air flow.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Currently there are two 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 two 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.
Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors
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
Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into a Drop-in or Flange-type
MAF sensor
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 927
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 928
Knock Sensor: Diagrams
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 929
Knock Sensor: Description and Operation
Engine Control Components
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.
Two Types of Knock Sensor (KS)
Two Types of Knock Sensor (KS)
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Knock Sensor: Service and Repair
Knock Sensor (KS) - 4.0L SOHC
Removal and Installation
1. Remove the intake manifold.
2. Disconnect the Knock Sensor (KS) electrical connector.
3. Remove the bolt and the KS.
- To install, tighten to 20 Nm (177 lb-in).
4. To install, reverse the removal procedure.
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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
Engine Control Components
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.
Typical Manifold Absolute Pressure (MAP) Sensor
Typical Manifold Absolute Pressure (MAP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description
and Operation
Oil Temperature Sensor For ECM: Description and Operation
Engine Control Components
Engine Oil Temperature (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.
Typical Thread Type Sensor
Typical EOT Sensor
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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 941
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 942
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 944
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #21
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 946
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
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Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22
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Sensor (HO2S) #11 > Page 949
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Heated Oxygen Sensor (HO2S)
Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S)
Engine Control Components
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.
Typical Heated Oxygen Sensor (HO2S)
Typical Heated Oxygen Sensor (HO2S)
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Heated Oxygen Sensor (HO2S) > Page 957
Oxygen Sensor: Description and Operation Universal Heated Oxygen Sensor (HO2S)
Engine Control Components
Universal Heated Oxygen Sensor (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 HO2S 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 (HO2S) and Catalyst Monitor Sensor - Exploded View
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor Exploded View
Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
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Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S)
Heated Oxygen Sensor (HO2S)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If the RH Heated Oxygen Sensor (HO2S) is being serviced, remove the 2 bolts and position the
heat shield aside.
3. Disconnect the HO2S electrical connector.
4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal.
Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S.
Installation
1. Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S.
2. Using the Exhaust Gas Oxygen Sensor Socket, install the HO2S.
- Calculate the correct torque wrench setting for the following torque.
- Using the Exhaust Gas Oxygen Sensor Socket, tighten to 41 Nm (30 lb-ft).
3. Connect the HO2S electrical connector.
4. If the RH HO2S is being serviced, position the heat shield and install the 2 bolts.
- Tighten to 20 Nm (177 lb-in).
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Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
Catalyst Monitor Sensor
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If the RH Catalyst Monitor Sensor (CMS) is being serviced, remove the 2 bolts and position the
heat shield aside.
3. Disconnect the CMS electrical connector.
4. NOTE: If necessary, lubricate the CMS with penetrating and lock lubricant to ease removal.
Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS.
Installation
1. Apply a light coat of anti-seize lubricant to the threads of the CMS.
2. Using the Exhaust Gas Oxygen Sensor Socket, install the CMS.
- Calculate the correct torque wrench setting for the following torque.
- Using the Exhaust Gas Oxygen Sensor Socket, tighten to 41 Nm (30 lb-ft).
3. Connect the CMS electrical connector.
4. If the RH CMS is being serviced, position the heat shield and install the 2 bolts.
- Tighten to 20 Nm (177 lb-in).
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Page 965
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Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and
Operation > Power Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
Engine Control Components
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 EPC
pressure during increased engine load, for example during parking maneuvers.
Typical Power Steering Pressure (PSP) Switch
Typical Power Steering Pressure (PSP) Switch
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Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and
Operation > Power Steering Pressure (PSP) Switch > Page 968
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
Engine Control Components
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 EPC pressure during increased engine load, for example, during
parking maneuvers.
Typical Power Steering Pressure (PSP) Sensor
Typical Power Steering Pressure (PSP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Description and Operation
Pressure Feedback Exhaust Sensor: Description and Operation
Engine Control Components
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
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
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.
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
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Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View
Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System
Components - Exploded View
Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
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Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View > Page 974
Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System
Module
Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC
Removal and Installation
1. Disconnect the EGR system module electrical and vacuum connectors.
2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting.
- To install, tighten to 40 Nm (30 lb-ft).
3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle
facing the intake manifold.
Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket.
- To install, tighten to 25 Nm (18 lb-ft).
4. NOTE: The EGR system module sealing surfaces are soft metals.
Carefully clean the EGR system module sealing surfaces.
5. To install, reverse the removal procedure.
- Install a new EGR system module gasket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC
P2135 Set
Throttle Position Sensor: Customer Interest A/C, Engine Controls - MIL ON/DTC P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
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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 > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC
P2135 Set > Page 983
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL
ON/DTC P2135 Set
Throttle Position Sensor: All Technical Service Bulletins A/C, Engine Controls - MIL ON/DTC
P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL
ON/DTC P2135 Set > Page 989
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 990
Throttle Position Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 991
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 992
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Electronic Throttle Body (ETB) Throttle Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle
Position Sensor
Engine Control Components
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. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) See: Powertrain Management/Computers and Control Systems/Electronic Throttle
Control Module/Description and Operation.
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Electronic Throttle Body (ETB) Throttle Position Sensor > Page 995
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
Engine Control Components
Throttle Position (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, four operating conditions are determined by the
PCM from the TP. These 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
Typical TP Sensor
Typical TP Sensor
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Page 996
Throttle Position Sensor: Service and Repair
Throttle Position (TP) Sensor
Removal
All vehicles
1. Remove the Air Cleaner (ACL) outlet pipe.
2. Disconnect the Throttle Position (TP) sensor electrical connector.
Vehicles equipped with a 4.6L (3V) engine
3. Disconnect the PCV hose from the heated PCV fitting.
4. Disconnect the heated PCV fitting electrical connector.
5. Remove the 2 bolts and the heated PCV fitting.
- Remove and discard the heated PCV fitting O-ring seal.
All vehicles
6. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts
because heat damage may occur. Damage
may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F).
NOTE: Do not use power tools.
Remove the TP sensor.
1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the
top TP sensor bolt ear reaches approximately
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Page 997
55°C (130°F), this should take no more than 3 minutes using a 1100-watt heat gun. The heat gun
should be about an 25.4 mm (1 in) away from the ETB.
2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature
measuring device, such as a digital temperature
laser or infrared thermometer, while heating the ETB.
3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard.
4. Using hand tools, remove the remaining bolt and discard.
5. Remove and discard the TP sensor.
Installation
All vehicles
1. NOTE: Do not use power tools.
Install the new TP sensor.
- Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in).
Vehicles equipped with a 4.6L (3V) engine
2. Install a new O-ring seal and position the heated PCV fitting and install the 2 bolts.
3. Connect the heated PCV fitting electrical connector.
4. Connect the PCV hose to the heated PCV fitting.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Page 998
All vehicles
5. Connect the TP sensor electrical connector.
6. Install the ACL outlet pipe.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations
Transmission Position Switch/Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 1002
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 1003
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 1004
Transmission Position Switch/Sensor: Adjustments
5R55S
Transmission Range (TR) Sensor Adjustment
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 Transmission Range (TR) sensor connector.
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable end from the manual control lever.
6. Remove the manual control lever nut and the manual control lever.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 1005
7. Loosen but do not remove the TR sensor screws.
8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence.
- Tighten to 8 Nm (71 lb-in).
9. Install the manual control lever and manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
11. Reconnect the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 1006
12. Reinstall the rubber boot over the TR 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 (V6-4.0L (2009))
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Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 1007
Transmission Position Switch/Sensor: Service and Repair
5R55S
Digital Transmission Range (TR) Sensor
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
3. Move the TR sensor connector boot back to gain access to the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 1008
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable from the manual control lever.
6. Remove the manual control lever nut.
7. Remove the TR sensor.
Installation
1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to
prevent damage to the sensor.
Install the TR sensor and loosely install the TR sensor screw and washer (2 required).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 1009
2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual control lever must be in the NEUTRAL position.
Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence. Tighten to 8 Nm (71 lb-in).
3. Install the manual control lever and the manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
5. Connect the TR sensor connector.
6. Move the TR sensor connector boot back over the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 1010
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 (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Output Shaft Speed (OSS) Sensor
Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor
Engine Control Components
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.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Output Shaft Speed (OSS) Sensor > Page 1015
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS)
Engine Control Components
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 speed, 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.
Typical Vehicle Speed Sensor (VSS)
Typical Vehicle Speed Sensor (VSS)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description
and Operation
Pressure Feedback Exhaust Sensor: Description and Operation
Engine Control Components
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
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
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.
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and
Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View
Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System
Components - Exploded View
Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
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Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and
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Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System
Module
Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC
Removal and Installation
1. Disconnect the EGR system module electrical and vacuum connectors.
2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting.
- To install, tighten to 40 Nm (30 lb-ft).
3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle
facing the intake manifold.
Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket.
- To install, tighten to 25 Nm (18 lb-ft).
4. NOTE: The EGR system module sealing surfaces are soft metals.
Carefully clean the EGR system module sealing surfaces.
5. To install, reverse the removal procedure.
- Install a new EGR system module gasket.
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Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 1027
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 1028
Accelerator Pedal Position Sensor: Description and Operation
Engine Control Components
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
There are two 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 two
pedal position signals make sure the PCM receives a correct input even if one 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 two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six
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 (TP) 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. For additional information, refer
to Torque Based Electronic Throttle Control (ETC) See: Powertrain Management/Computers and
Control Systems/Electronic Throttle Control Module/Description and Operation.
2-Track APP Sensor
Typical 2-Track APP Sensor
3-Track APP Sensor
There are three 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 three pedal position signals make sure the PCM
receives a correct input even if one 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 two reference voltage circuits, two signal
return circuits, and three signal circuits (a total of seven 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. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) See: Powertrain Management/Computers and Control Systems/Electronic Throttle
Control Module/Description and Operation.
3-Track APP Sensor
Typical 3-Track APP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
Air Flow Meter/Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1032
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1033
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1034
Air Flow Meter/Sensor: Description and Operation
Engine Control Components
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 (TCC) 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 IAT sensor.
The hot wire electronic sensing element must be replaced as an assembly. Replacing only the
element may change the air flow calibration.
Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT
Sensor Wire Where Applicable) Terminals
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
Typical Mass Air Flow (MAF) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1035
Typical Drop-in Mass Air Flow (MAF) Sensor
Typical Drop-in Mass Air Flow (MAF) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1036
Air Flow Meter/Sensor: Service and Repair
Mass Air Flow (MAF) Sensor - 4.0L SOHC
Removal and Installation
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the 2 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 (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations
Fuel Pressure Sensor/Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page
1040
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page
1041
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page
1042
Fuel Pressure Sensor/Switch: Description and Operation
Engine Control Components
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.
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page
1043
Fuel Pressure Sensor/Switch: Service and Repair
Fuel Rail Pressure and Temperature Sensor - 4.0L SOHC
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.
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.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Remove the intake manifold.
4. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
5. Remove the 2 bolts and the fuel rail pressure and temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. Remove and discard the O-ring seal.
7. NOTICE: Use an O-ring seal made of special fuel resistant material. Fuel will damage ordinary
O-ring seals and may cause the fuel
system to leak.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page
1044
NOTICE: Do not reuse the O-ring seal. The removal and installation process may damage the used
O-ring seals and cause the fuel system to leak.
To install, reverse the removal procedure.
- Lubricate the new O-ring seal with clean engine oil.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations
Fuel Temperature Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1048
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1049
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1050
Fuel Temperature Sensor: Description and Operation
Engine Control Components
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.
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1051
Fuel Temperature Sensor: Service and Repair
Fuel Rail Pressure and Temperature Sensor - 4.0L SOHC
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.
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.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Remove the intake manifold.
4. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
5. Remove the 2 bolts and the fuel rail pressure and temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. Remove and discard the O-ring seal.
7. NOTICE: Use an O-ring seal made of special fuel resistant material. Fuel will damage ordinary
O-ring seals and may cause the fuel
system to leak.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1052
NOTICE: Do not reuse the O-ring seal. The removal and installation process may damage the used
O-ring seals and cause the fuel system to leak.
To install, reverse the removal procedure.
- Lubricate the new O-ring seal with clean engine oil.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1056
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1057
Inertia Fuel Shutoff Switch: Description and Operation
Engine Control Components
Inertia Fuel Shut-off (IFS) Switch
The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is
to shut off the fuel pump if a collision occurs. It consists of a steel cone held in place by a magnet.
When a sharp impact occurs, the cone 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.
Typical Inertia Fuel Shut-off (IFS) Switch
Typical Inertia Fuel Shut-off (IFS) Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 1058
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.
NOTE: 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 2 bolts and the IFS switch.
- To install, tighten to 2 Nm (18 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC
P2135 Set
Throttle Position Sensor: Customer Interest A/C, Engine Controls - MIL ON/DTC P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC
P2135 Set > Page 1067
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL
ON/DTC P2135 Set
Throttle Position Sensor: All Technical Service Bulletins A/C, Engine Controls - MIL ON/DTC
P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL
ON/DTC P2135 Set > Page 1073
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 1074
Throttle Position Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 1075
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 1076
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Electronic Throttle Body (ETB) Throttle Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle
Position Sensor
Engine Control Components
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. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) See: Powertrain Management/Computers and Control Systems/Electronic Throttle
Control Module/Description and Operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Electronic Throttle Body (ETB) Throttle Position Sensor > Page 1079
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
Engine Control Components
Throttle Position (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, four operating conditions are determined by the
PCM from the TP. These 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
Typical TP Sensor
Typical TP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Page 1080
Throttle Position Sensor: Service and Repair
Throttle Position (TP) Sensor
Removal
All vehicles
1. Remove the Air Cleaner (ACL) outlet pipe.
2. Disconnect the Throttle Position (TP) sensor electrical connector.
Vehicles equipped with a 4.6L (3V) engine
3. Disconnect the PCV hose from the heated PCV fitting.
4. Disconnect the heated PCV fitting electrical connector.
5. Remove the 2 bolts and the heated PCV fitting.
- Remove and discard the heated PCV fitting O-ring seal.
All vehicles
6. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts
because heat damage may occur. Damage
may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F).
NOTE: Do not use power tools.
Remove the TP sensor.
1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the
top TP sensor bolt ear reaches approximately
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Page 1081
55°C (130°F), this should take no more than 3 minutes using a 1100-watt heat gun. The heat gun
should be about an 25.4 mm (1 in) away from the ETB.
2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature
measuring device, such as a digital temperature
laser or infrared thermometer, while heating the ETB.
3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard.
4. Using hand tools, remove the remaining bolt and discard.
5. Remove and discard the TP sensor.
Installation
All vehicles
1. NOTE: Do not use power tools.
Install the new TP sensor.
- Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in).
Vehicles equipped with a 4.6L (3V) engine
2. Install a new O-ring seal and position the heated PCV fitting and install the 2 bolts.
3. Connect the heated PCV fitting electrical connector.
4. Connect the PCV hose to the heated PCV fitting.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Page 1082
All vehicles
5. Connect the TP sensor electrical connector.
6. Install the ACL outlet pipe.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
> Page 1092
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
> Page 1093
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1094
Camshaft Position Sensor: Description and Operation
Engine Control Components
Camshaft Position (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 two CMP sensors are equipped with variable camshaft timing (VCT). The second
sensor is used to identify the position of the camshaft on bank 2.
There are two types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin
Hall-effect type sensor.
Typical Variable Reluctance CMP Sensor
Typical Variable Reluctance CMP Sensor
Typical Hall-effect CMP Sensor
Typical Hall-effect CMP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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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 - 4.0L SOHC
Removal and Installation
1. Disconnect the Camshaft Position (CMP) sensor electrical connector.
2. Remove the bolt and the CMP sensor.
- To install, tighten to 6 Nm (53 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1099
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1100
Crankshaft Position Sensor: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1101
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1102
Crankshaft Position Sensor: Description and Operation
Engine Control Components
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.
Typical Crankshaft Position (CKP) Sensor
Typical Crankshaft Position (CKP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1103
Crankshaft Position Sensor: Service and Repair
Crankshaft Position (CKP) Sensor - 4.0L SOHC
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
3. Remove the 2 bolts and the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. NOTE: Be sure the sensor wiring is routed away from the battery cable.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Ignition Lock Cylinder - Functional
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.
NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a
new lock cylinder using the appropriate lock repair package. The lock repair package includes a
detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. With the ignition switch in the RUN position, press the locking pin with a suitable tool and remove
the ignition lock cylinder.
2. If a new lock cylinder with keys is replaced, the new Passive Anti-Theft System (PATS) keys
must be programmed.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional > Page 1109
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Ignition Lock Cylinder - Non Functional
Removal
1. Remove the Passive Anti-Theft System (PATS) transceiver.
2. Remove the ignition lock cylinder.
- Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
- Use a 3/8-inch diameter drill bit to drill down the middle of the ignition lock key slot until the
ignition lock cylinder breaks loose.
- Remove and discard the ignition lock cylinder and drill shavings from the steering column.
3. Remove the bearing retainer.
4. Remove the steering column lock housing bearing and steering column lock gear.
Installation
1. Thoroughly clean all drill shavings from the steering column and inspect it for damage.
2. Install a new ignition lock cylinder.
- Verify the ignition lock cylinder operation.
3. Program the new PATS keys.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1113
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1114
Knock Sensor: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1115
Knock Sensor: Description and Operation
Engine Control Components
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.
Two Types of Knock Sensor (KS)
Two Types of Knock Sensor (KS)
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Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1116
Knock Sensor: Service and Repair
Knock Sensor (KS) - 4.0L SOHC
Removal and Installation
1. Remove the intake manifold.
2. Disconnect the Knock Sensor (KS) electrical connector.
3. Remove the bolt and the KS.
- To install, tighten to 20 Nm (177 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > RH Front Impact Severity Sensor
Impact Sensor: Locations RH Front Impact Severity Sensor
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1122
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1123
Impact Sensor: Locations LH Front Impact Severity Sensor
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1124
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1125
Impact Sensor: Locations Side Impact Sensor, Second Row Driver Side
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1126
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1127
Impact Sensor: Locations Side Impact Sensor, Second Row Passenger Side
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1128
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1129
Impact Sensor: Locations
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1130
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1131
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1132
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1133
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1134
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1135
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1136
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1137
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Locations > RH Front Impact Severity Sensor > Page 1138
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Diagrams > Side Impact Sensor, First Row Driver Side
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 1141
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 1142
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 1143
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 1144
Impact Sensor: Diagrams
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Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 1145
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 1146
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Front Impact Severity Sensor
Impact Sensor: Service and Repair Front Impact Severity Sensor
Front Impact Severity Sensor
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and
Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering
in the General Procedures.
2. Remove the 4 pin-type retainers and 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 front impact severity sensor. To install, tighten to 12 Nm (106 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Service and Repair > Front Impact Severity Sensor > Page 1149
5. To install, reverse the removal procedure.
6. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and
Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering
in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Front Impact Severity Sensor > Page 1150
Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar
Side Impact Sensor - C-Pillar, Explorer, Mountaineer
NOTE: RH shown, LH similar.
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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
NOTE: The LH and RH C-pillar mounted side impact sensors are not interchangeable.
1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and
Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering
in the General Procedures.
2. Remove the rear door scuff plate.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Service and Repair > Front Impact Severity Sensor > Page 1151
NOTE: 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 (106 lb-in).
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. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and
Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering
in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Front Impact Severity Sensor > Page 1152
Impact Sensor: Service and Repair Side Impact Sensor - Front Door
Side Impact Sensor - Front Door
NOTE: LH side shown, RH similar.
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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and
Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering
in the General Procedures.
2. Remove the front interior door trim panel.
3. Detach the rearward lower corner of the weathershield on the door to access the side impact
sensor (pressure sensor).
4. Disconnect the electrical connector.
5. Remove the bolt and 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. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and
Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering
in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations > Safety Belt Buckle Switch, Passenger
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 1157
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Safety Belt Buckle Switch, Driver
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 1160
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > OCS Rail 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > OCS Rail 1 > Page 1165
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 1166
Seat Occupant Sensor: Service and Repair
Occupant Classification Sensor
NOTE: Outboard Occupant Classification Sensor (OCS) rail shown, inboard similar.
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.
WARNING: 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.
WARNING: 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.
WARNING: 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 1167
crash.
NOTICE: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Remove the front passenger seat.
2. NOTICE: 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 Occupant Classification Sensor (OCS) rail position, electrical wiring routing, wiring,
connector and wiring retainers for installation.
On the affected side, detach the 2 OCS rail wiring retainers and using a suitable tool, release the
tab and disconnect the OCS rail electrical connector.
3. If equipped, disconnect the power seat track motor electrical connector.
4. Move the seat to the forward stop position.
- If equipped with a power seat track, apply power and ground to the pins shown.
5. Remove the 2 rear bolts from the OCS rail.
6. Move the seat to the rearward stop position.
- If equipped with a power seat track, apply power and ground to the pins shown.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 1168
7. NOTE: Note the locator tab position where the OCS rail goes through the rail shield and into the
rear seat track mounting point for installation.
Remove the 2 front bolts and OCS rail and shield.
Installation
NOTE: If installing a new seat track, position the seat track where the seat will be in the full
rearward position before installing the OCS rails.
NOTE: 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.
NOTICE: 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: Make sure the OCS rail shield is seated correctly on the OCS rail.
Install the shield on the OCS rail, and install the OCS rail and shield on the seat track with the
locator tab aligned correctly as shown.
2. Hold the OCS rail and shield firmly in position and install the front mounting position rear bolt.
- Tighten to 25 Nm (18 lb-ft).
3. Hold the OCS rail and shield firmly in position and install the front mounting position front bolt.
- Tighten to 25 Nm (18 lb-ft).
4. Move the seat to the forward stop position.
- If equipped with a power seat track, apply power and ground to the pins shown.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 1169
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, route the 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 component, carry out the Occupant Classification Sensor
(OCS) System Zero Seat Weight Test and prove out the SRS. For additional information, refer to
Occupant Classification Sensor (OCS) System Zero Seat Weight Test See: Restraint Systems/Air
Bag Systems/Testing and Inspection/Component Tests and General Diagnostics.
- If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS)
System Reset procedure and prove out the SRS. For additional information, refer to Occupant
Classification Sensor (OCS) System Reset See: Restraint Systems/Air Bag Systems/Service and
Repair/Occupant Classification Sensor (OCS) System Reset.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
NOTE: Power seat shown, manual seat similar.
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.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Position the front seat to the rearmost and upward position.
2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and
Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering
in the General Procedures.
3. Disconnect the seat position sensor 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.
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. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and
Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering
in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Page 1176
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Ignition Lock Cylinder - Functional
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.
NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a
new lock cylinder using the appropriate lock repair package. The lock repair package includes a
detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. With the ignition switch in the RUN position, press the locking pin with a suitable tool and remove
the ignition lock cylinder.
2. If a new lock cylinder with keys is replaced, the new Passive Anti-Theft System (PATS) keys
must be programmed.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page
1183
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Ignition Lock Cylinder - Non Functional
Removal
1. Remove the Passive Anti-Theft System (PATS) transceiver.
2. Remove the ignition lock cylinder.
- Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
- Use a 3/8-inch diameter drill bit to drill down the middle of the ignition lock key slot until the
ignition lock cylinder breaks loose.
- Remove and discard the ignition lock cylinder and drill shavings from the steering column.
3. Remove the bearing retainer.
4. Remove the steering column lock housing bearing and steering column lock gear.
Installation
1. Thoroughly clean all drill shavings from the steering column and inspect it for damage.
2. Install a new ignition lock cylinder.
- Verify the ignition lock cylinder operation.
3. Program the new PATS keys.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
Neutral Safety Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 1187
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 1188
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 1194
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power
Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
Engine Control Components
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 EPC
pressure during increased engine load, for example during parking maneuvers.
Typical Power Steering Pressure (PSP) Switch
Typical Power Steering Pressure (PSP) Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power
Steering Pressure (PSP) Switch > Page 1197
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
Engine Control Components
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 EPC pressure during increased engine load, for example, during
parking maneuvers.
Typical Power Steering Pressure (PSP) Sensor
Typical Power Steering Pressure (PSP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 1201
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 1202
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 1207
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 1208
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 See: Instrument Panel, Gauges and
Warning Indicators/Tire Monitoring System/Testing and Inspection/Programming and Relearning.
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire
Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and
appliance operation, cellular telephones, remote transmitters, power inverters and portable
entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to
activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not
respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate
the same sensor again.
NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not
recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and
the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire
procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for
front and rear tires, tire rotation will not affect the system.
1. Turn the ignition switch to the OFF position, then press and release the brake pedal.
2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
3. Press and release the brake pedal.
4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
- The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully. If equipped, the message center will display TRAIN LF TIRE.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in
place 180 degrees from the valve stem.
Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from
the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The
horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1214
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall opposite (180 degrees) from the
valve stem and press and release the test button to train the RF tire pressure sensor.
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 identifiers 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 carry out
the SJB On-Demand Self Test.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1215
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 Tire Pressure Monitor 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 Tire Pressure Monitor 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. See: Instrument Panel, Gauges and Warning Indicators/Tire
Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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. NOTICE: 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. For additional information, refer to Wheel and Tire See:
Maintenance/Wheels and Tires/Service and Repair/Overhaul.
2. NOTICE: 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.
3. NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1218
4. Remove the sensor.
Assembly
1. NOTICE: 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.
3. NOTICE: 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. For additional information, refer to Wheel and Tire See:
Maintenance/Wheels and Tires/Service and Repair/Overhaul.
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 See: Instrument Panel, Gauges and Warning Indicators/Tire
Monitoring System/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1219
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
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 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 See: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1220
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 in) 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. NOTICE: 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.
Using wheel and tire cleaner, clean the area where the sensor and cradle are to be installed.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1221
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. NOTICE: 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 in) away from the sensor and tighten the worm gear.
- Tighten to 3 Nm (27 lb-in).
6. NOTICE: 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. For additional information, refer to Wheel and Tire. See:
Maintenance/Wheels and Tires/Service and Repair/Overhaul
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. See: Instrument Panel, Gauges and Warning Indicators/Tire
Monitoring System/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation
Brake Switch - TCC: Description and Operation
Engine Control Components
Brake Pedal Position (BPP) Switch
The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal
to the PCM indicating the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Typical BPP Switch
Typical BPP Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation
Transmission Mode Switch: Description and Operation
Engine Control Components
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.
Typical Transmission Control Switch (TCS) (Column Shift)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS) (Floor Shift)
Typical Transmission Control Switch (TCS)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control
Switch (TCS)
Transmission Mode Switch: Service and Repair Transmission Control Switch (TCS)
External Controls
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) is a momentary contact switch located on the selector
lever knob. Pushing the TCS will either disengage or engage the overdrive function of the
transmission. If OVERDRIVE is disengaged, the message Overdrive (O/D) OFF will illuminate on
the Instrument Cluster (IC).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control
Switch (TCS) > Page 1232
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch
Transmission Control (TC) Switch
Removal
1. Remove the selector lever knob. For additional information, refer to Selector Lever Knob See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Shifter A/T/Service and Repair/Selector Lever Knob.
2. Remove the Transmission Control Switch (TCS) from the knob.
Installation
1. Install the TCS into the selector lever knob.
2. Install the selector lever knob. For additional information, refer to Selector Lever Knob See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Shifter A/T/Service and Repair/Selector Lever Knob.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1236
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1237
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1238
Transmission Position Switch/Sensor: Adjustments
5R55S
Transmission Range (TR) Sensor Adjustment
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 Transmission Range (TR) sensor connector.
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable end from the manual control lever.
6. Remove the manual control lever nut and the manual control lever.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1239
7. Loosen but do not remove the TR sensor screws.
8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence.
- Tighten to 8 Nm (71 lb-in).
9. Install the manual control lever and manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
11. Reconnect the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1240
12. Reinstall the rubber boot over the TR 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 (V6-4.0L (2009))
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 1241
Transmission Position Switch/Sensor: Service and Repair
5R55S
Digital Transmission Range (TR) Sensor
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
3. Move the TR sensor connector boot back to gain access to the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1242
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable from the manual control lever.
6. Remove the manual control lever nut.
7. Remove the TR sensor.
Installation
1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to
prevent damage to the sensor.
Install the TR sensor and loosely install the TR sensor screw and washer (2 required).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1243
2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual control lever must be in the NEUTRAL position.
Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence. Tighten to 8 Nm (71 lb-in).
3. Install the manual control lever and the manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
5. Connect the TR sensor connector.
6. Move the TR sensor connector boot back over the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1244
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 (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1249
Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1250
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1251
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Output Shaft Speed (OSS)
Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Output Shaft Speed (OSS)
Sensor > Page 1254
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Output Shaft Speed (OSS)
Sensor > Page 1255
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed
(TSS) Sensor
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed
(TSS) Sensor > Page 1258
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the Turbine Shaft Speed (TSS) sensor 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 (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed
(TSS) Sensor > Page 1259
Installation
All vehicles
1. Inspect the TSS O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the TSS sensor connector.
3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever bracket and selector lever bracket screws.
- Tighten to 40 Nm (30 lb-ft).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed
(TSS) Sensor > Page 1260
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed
(TSS) Sensor > Page 1261
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed
(TSS) Sensor > Page 1262
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
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 connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed
(TSS) Sensor > Page 1263
9. Remove the OSS sensor.
1. Remove the OSS sensor screw.
2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
All vehicles
1. Inspect the OSS O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the OSS sensor connector.
3. Connect the HO2S connector to the transmission case.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed
(TSS) Sensor > Page 1264
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever cable bracket and selector lever cable bracket
screws.
- 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.
7. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
8. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed
(TSS) Sensor > Page 1265
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed
(TSS) Sensor > Page 1266
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed
(TSS) Sensor > Page 1267
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the intermediate shaft speed sensor 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 (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed
(TSS) Sensor > Page 1268
Installation
All vehicles
1. Inspect the O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the intermediate shaft speed sensor connector.
3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever cable bracket and selector lever cable bracket
screws.
- Tighten to 40 Nm (30 lb-ft).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed
(TSS) Sensor > Page 1269
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Master Window Adjust Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Master Window Adjust Switch > Page 1275
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Master Window Adjust Switch > Page 1276
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Master Window Adjust Switch > Page 1277
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch
Power Window Switch: Diagrams Master Window Adjust Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 1280
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 1281
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 1282
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 1283
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 1286
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1287
Power Window Switch: Testing and Inspection Window Adjust Switches - Passenger Side and
Rear Doors
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1288
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 1289
Power Window Switch: Service and Repair
Window Control Switch
Removal and Installation
1. Remove the interior door handle cover.
2. Lift the window control switch bezel upward to release the clips.
3. Disconnect the window control switch electrical connectors from the window control switch.
4. Disconnect the window control switch from the window control switch bezel to remove.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Locations > Page 1294
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Locations > Page 1295
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations
Windshield Washer Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 1299
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 1300
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1303
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1304
Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1305
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Page 1306
Windshield Washer Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Removal and Installation
NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Remove the 2 screws and the steering column opening cover.
2. Remove the 3 screws and the upper and lower steering column shrouds.
3. Disconnect the multifunction switch electrical connector.
4. Remove the 2 multifunction switch screws and the multifunction switch.
- To install, tighten to 3 Nm (27 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations
Wiper Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 1310
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 1311
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Testing and Inspection > Multifunction Switch > Page 1314
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Testing and Inspection > Multifunction Switch > Page 1315
Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Testing and Inspection > Multifunction Switch > Page 1316
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Testing and Inspection > Page 1317
Wiper Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Removal and Installation
NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Remove the 2 screws and the steering column opening cover.
2. Remove the 3 screws and the upper and lower steering column shrouds.
3. Disconnect the multifunction switch electrical connector.
4. Remove the 2 multifunction switch screws and the multifunction switch.
- To install, tighten to 3 Nm (27 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications
Alignment: Specifications Alignment Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications >
Page 1323
Alignment: Specifications Ball Joint Deflection, Ride Height, Thrust Angle, and Vehicle Lean
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications >
Page 1324
Alignment: Specifications Torque Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber
Alignment: Description and Operation Camber
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page
1327
Alignment: Description and Operation Caster
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.
Caster
Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed
from the side. The caster specifications will give the vehicle the best directional stability
characteristics when loaded and driven. The caster setting is not related to tire wear.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page
1328
Alignment: Description and Operation Drift/Pull
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.
Drift/Pull
Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep
the vehicle going straight.
Drift describes what a vehicle with this condition does with hands off the steering wheel.
- A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.
- Drift/pull may be induced by conditions external to the vehicle, such as wind or road camber.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page
1329
Alignment: Description and Operation Nibble
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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page
1330
Alignment: Description and Operation
Camber
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
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.
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.
Drift/Pull
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page
1331
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.
Nibble
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.
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
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.
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.
Shimmy
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.
Shimmy
Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel
resulting from large, side-to-side (lateral) tire/wheel movements.
Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire
contacts pot holes or irregularities in the road surface.
Toe
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.
Toe
Positive Toe (Toe In)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page
1332
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.
Incorrect Thrust Angle (Dogtracking)
Wander
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.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel
corrections to maintain a straight path down a level road.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: A caster split adjustment can be made by loosening the LF lower arm rearward nut and
adjusting the rear of the LF lower arm.
Remove and discard the LF lower control arm rearward nut.
5. NOTE: Do not fully tighten the nut and bolt at this time.
Install a new LF lower 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.
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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1335
Alignment: Service and Repair Ride Height Measurement
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 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 2).
3. Position the surface gauge on the same flat, level surface as used in Step 1, adjust the gauge
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 3).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1336
5. Subtract measurement 3 from measurement 2 to obtain the front ride height.
- Refer to Specifications.
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 2).
2. Measure the distance between the flat level surface and the center of the shock absorber lower
bolt (measurement 3).
3. Subtract measurement 3 from measurement 2 to obtain the rear ride height.
- Refer to Specifications.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1337
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. NOTICE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1338
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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1339
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 in) 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.
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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Specifications
Fuel Pressure: Specifications
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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Specifications > Page 1344
Fuel Pressure: Testing and Inspection
Fuel System Pressure Test
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.
WARNING: 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.
WARNING: 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. Release the fuel system pressure. For additional information, refer to Fuel System Pressure
Release See: Fuel Filter/Fuel Pressure Release/Service
and Repair.
2. Disconnect the battery ground cable.
3. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. For additional information, refer
to Spring Lock Couplings See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Spring Lock
Couplings.
4. NOTE: 4.6L shown, 4.0L similar.
Install the Fuel Pressure Test Kit in line between the fuel supply tube and fuel rail.
5. NOTE: The Inertia Fuel Shutoff (IFS) switch electrical connector was disconnected during fuel
system pressure release.
Connect the IFS switch electrical connector.
6. Connect the battery ground cable.
7. 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.
8. Test the fuel system pressure to make sure it is within the specified range. For additional
information, refer to Specifications.
9. NOTE: 4.6L shown, 4.0L similar.
NOTE: 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 Fuel Pressure Test
Kit and relieve the fuel system pressure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Specifications > Page 1345
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 Hot Idle ............................................................................................................
.......................................................................................... 750 - 820 RPM
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Intake Air System Components - Exploded View
Air Filter Element: Service and Repair Intake Air System Components - Exploded View
Intake Air System Components - Exploded View
Coolant Expansion Tank
Intake Air System Components (4.0L SOHC)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 1354
Intake Air System Components - 4.6L (3V)
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 1355
Air Filter Element: Service and Repair Air Cleaner Element
Air Cleaner Element
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 element.
6. NOTE: Clean the inside of the ACL tray.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
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. 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.
NOTE: It may be necessary to reposition the lower end of the door jam weatherstripping to remove
the front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the Inertia Fuel Shutoff (IFS) switch electrical connector.
4. Start the engine and allow it to idle until it stalls.
5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail
pressure has been released.
6. Turn the ignition switch to the OFF position.
7. When the fuel system service is complete, reconnect the IFS switch electrical connector.
8. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before
starting the engine.
9. Start the vehicle and check the fuel system for leaks.
10. Install the front passenger side interior kick panel.
11. Install the front passenger door frame scuff plate.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Firing Order: Specifications
Firing order...........................................................................................................................................
..................................................................1-4-2-5-3-6
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > System
Information > Specifications
Ignition Timing: Specifications
Base ignition timing................................................................................................................10
degrees Before Top Dead Center (BTDC), Non-adjustable
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service and Repair
Ignition Cable: Service and Repair
Spark Plug Wires
Removal and Installation
1. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible
damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. For additional
information, refer to the Cylinder-to-Coil Terminal Relationship, Engine Ignition See: Powertrain
Management/Ignition System/Description and Operation in the Description and Operation.
Squeeze the locking tabs and twist while pulling upward to disconnect the 6 spark plug wires from
the ignition coil.
2. Detach the spark plug wires from the spark plug wire retainers.
3. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible
damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct spark plug.
With a twisting motion, use the Spark Plug Wire Remover to pull the spark plug wires from the
spark plugs.
4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Gap
Spark Plug: Specifications Gap
Item.......................................................................................................................................................
...............................................................Specification
Spark Plug Gap....................................................................................................................................
....................................1.32-1.42 mm (0.052-0.056 in)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Gap > Page 1373
Spark Plug: Specifications Torque Specifications
Spark plugs...........................................................................................................................................
........................................................17 Nm (150 lb-in)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1374
Spark Plug: Application and ID
Item.......................................................................................................................................................
...............................................................Specification
Spark Plug type....................................................................................................................................
....................................................................AGSF24N
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1375
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.
- Install a new 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.
5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine
damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized
installation of a heli-coil insert in place of the spark plug threads. Install a new spark plug.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1376
6. Inspect for overheating, identified by white or light gray spots and 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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Service and Repair > Engine Ignition Components - Exploded View
Spark Plug: Service and Repair Engine Ignition Components - Exploded View
Engine Ignition Components - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Service and Repair > Engine Ignition Components - Exploded View > Page 1379
Spark Plug: Service and Repair Spark Plugs
Spark Plugs
Removal and Installation
1. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible
damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct spark plug. Refer to the Cylinder-to-Coil
Terminal Relationship, Engine Ignition See: Powertrain Management/Ignition System/Description
and Operation in the Description and Operation.
With a twisting motion, use the Spark Plug Wire Remover to pull the spark plug wire from the spark
plug.
2. NOTE: Use compressed air to remove any foreign material from the spark plug wells before
removing the spark plugs.
Remove the spark plugs.
- To install, tighten to 17 Nm (150 lb-in).
3. Use a suitable spark plug gap tool to check and adjust the spark plug gap.
4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications
Compression Check: Specifications
Compression Test - Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart.
Compression Pressure Limit Chart
If one or more cylinders reads 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 within 75% of the highest reading.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 1383
Compression Check: Testing and Inspection
Engine
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 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
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the
pistons in the low-reading cylinders. Repeat the
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 1384
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 within 75% of the highest reading.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams
Drive Belt: Diagrams
Accessory Drive Belt Routing
Front End Accessory Drive (FEAD) - 4.0L SOHC
Front End Accessory Drive (FEAD) - 4.6L (3V)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Noise/Flutter
Drive Belt: Testing and Inspection Drive Belt - Noise/Flutter
Accessory Drive
Drive Belt - Noise/Flutter
NOTICE: 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.
- the A/C anti-slugging strategy executes after a long hot heat soak.
- 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Noise/Flutter > Page 1390
Drive Belt: Testing and Inspection Drive Belt - Incorrect Installation
Accessory Drive
Drive Belt - Incorrect Installation
NOTICE: 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
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Front End Accessory
Drive (FEAD) - Exploded View
Drive Belt: Service and Repair Front End Accessory Drive (FEAD) - Exploded View
Front End Accessory Drive (FEAD) - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Front End Accessory
Drive (FEAD) - Exploded View > Page 1393
Drive Belt: Service and Repair Accessory Drive Belt
Accessory Drive Belt - 4.0L SOHC
Removal and Installation
1. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt.
2. To install, reverse the removal procedure.
- For correct belt routing, refer to Accessory Drive See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Description and Operation, Accessory Drive Belt Routing,
Front End Accessory Drive (FEAD) - 4.0L SOHC in the Description and Operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Service and Repair > Intake Air System Components - Exploded View
Air Filter Element: Service and Repair Intake Air System Components - Exploded View
Intake Air System Components - Exploded View
Coolant Expansion Tank
Intake Air System Components (4.0L SOHC)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Service and Repair > Intake Air System Components - Exploded View > Page 1400
Intake Air System Components - 4.6L (3V)
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Service and Repair > Intake Air System Components - Exploded View > Page 1401
Air Filter Element: Service and Repair Air Cleaner Element
Air Cleaner Element
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 element.
6. NOTE: Clean the inside of the ACL tray.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair
Cabin Air Filter: Service and Repair
The air distribution system of this vehicle cannot be equipped with a cabin air filter.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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: 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.
- Carry out the Evaporative Emission System Leak Test. For additional information, refer to
Evaporative Emission System Leak Test See: Powertrain Management/Emission Control
Systems/Evaporative Emissions System/Testing and Inspection.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S
Fluid Filter - A/T: Service and Repair 5R55S
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 pan drain plug and drain the transmission fluid.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S > Page 1412
5. Remove and discard the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet.
Installation
1. NOTICE: Damage may occur to transmission fluid filter seals if they are not lubricated with
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 filter.
- Tighten to 10 Nm (89 lb-in).
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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S > Page 1413
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 (97 lb-in).
6. Install the transmission fluid pan drain plug.
- Tighten to 26 Nm (19 lb-ft).
7. Partially fill the transmission. For additional information, refer to Transmission Fluid Exchange
See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Procedures/5R55S/Transmission Fluid Exchange or
Transmission Fluid Drain and Refill See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Procedures/5R55S/Transmission Fluid Drain and
Refill.
Transmission Filter - In Line
Transmission Filter - In Line
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S > Page 1414
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.
3. Using the Transmission Disconnect Tool, disconnect the transmission fluid cooler connector.
4. Remove the section of the transmission fluid cooler tube at the second flare.
- Clean and de-burr 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 one and one-half turns to seat
the ferrule in the connector.
6. Remove the section of the transmission fluid cooler hose as illustrated.
7. NOTICE: 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 tube with the red arrow on the transmission fluid filter pointing
away from the transmission fluid cooler and toward the transmission (the transmission fluid return
tube 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.
NOTICE: Do not install any transmission fluid cooler hoses or transmission fluid cooler tubes with a
bend entering the transmission fluid
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S > Page 1415
filter greater than 60 degrees. Doing so can block transmission fluid flow and cause internal
transmission damage.
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 transmission fluid.
- Verify for correct operation.
- Check the filter for leaks.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S > Page 1416
Fluid Filter - A/T: Service and Repair 6R80
Fluid Pan, Gasket and Filter
Removal
NOTICE: The use of any transmission fluid other 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 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. Remove the transmission fluid pan gasket.
5. Remove and discard the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S > Page 1417
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 seal is in the case,
carefully remove the seal without scratching the case.
2. Make sure that the seal is on the transmission fluid filter and lubricate the seal with automatic
transmission fluid.
3. NOTE: The transmission fluid filter may be reused if no excessive contamination is indicated.
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.
Install a new transmission fluid pan gasket if required.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S > Page 1418
6. Install the transmission fluid pan and tighten the bolts in a crisscross pattern.
- Tighten to 12 Nm (106 lb-in).
7. Using the Adding Additional Transmission Fluid procedure, fill and check the transmission fluid.
For additional information, refer to Transmission
Fluid Drain and Refill See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service
and Repair/Procedures/6R80/Transmission Fluid Drain and Refill.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
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. 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.
NOTE: It may be necessary to reposition the lower end of the door jam weatherstripping to remove
the front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the Inertia Fuel Shutoff (IFS) switch electrical connector.
4. Start the engine and allow it to idle until it stalls.
5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail
pressure has been released.
6. Turn the ignition switch to the OFF position.
7. When the fuel system service is complete, reconnect the IFS switch electrical connector.
8. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before
starting the engine.
9. Start the vehicle and check the fuel system for leaks.
10. Install the front passenger side interior kick panel.
11. Install the front passenger door frame scuff plate.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
Coolant Line/Hose: Service and Repair
Coolant Crossover Manifold Assembly
Accessory Drive Belt
Generator
Coolant Crossover Manifold Assembly
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair >
Page 1427
Removal and Installation
1. Drain the engine cooling system. For additional information, refer to Cooling System Draining,
Filling and Bleeding See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair/Procedures/Cooling System Draining, Filling and
Bleeding.
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).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair >
Page 1428
- Install new gaskets.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Customer Interest for Heater Hose: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC P2135 Set
Heater Hose: Customer Interest A/C, Engine Controls - MIL ON/DTC P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Customer Interest for Heater Hose: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC P2135 Set > Page 1437
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC P2135 Set
Heater Hose: All Technical Service Bulletins A/C, Engine Controls - MIL ON/DTC P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC P2135 Set >
Page 1443
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 - 4.0L SOHC
Removal and Installation
1. Recover the refrigerant.
2. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket.
- To install, tighten to 7 Nm (62 lb-in).
3. Remove the compressor discharge fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (133 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 compressor-to-condenser discharge line.
7. To install, reverse the removal procedure.
- Install a new gasket seal and O-ring seals.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1448
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
8. Evacuate, leak test and charge the refrigerant system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1449
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1450
- 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1451
Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Front
Auxiliary Evaporator Outlet and Inlet Line - Front
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1452
6. Remove the front auxiliary evaporator line fitting nuts and disconnect the fittings.
- Discard the O-ring seals.
- To install, tighten to 8 Nm (71 lb-in).
7. Remove the 3 auxiliary line bracket nuts.
- To install, tighten to 6 Nm (53 lb-in).
8. Remove the 3 auxiliary line bracket bolts.
- To install, tighten to 6 Nm (53 lb-in).
9. Remove the 6 auxiliary line brackets.
10. Remove the front auxiliary evaporator outlet and inlet lines.
11. To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
12. Evacuate, leak test and charge the refrigerant system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1453
Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Rear
Auxiliary Evaporator Outlet and Inlet Line - Rear
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1454
6. Remove the 2 rear auxiliary evaporator line front fitting nuts and disconnect the fittings.
- Discard the O-ring seals.
- To install, tighten to 8 Nm (71 lb-in).
7. Remove the 2 rear auxiliary evaporator line rear fitting nuts and disconnect the fittings.
- Discard the O-ring seals.
- To install, tighten to 8 Nm (71 lb-in).
8. Remove the auxiliary line bracket nut.
- To install, tighten to 6 Nm (53 lb-in).
9. Remove the 2 auxiliary line brackets.
10. Remove the rear auxiliary evaporator outlet line.
11. Remove the rear auxiliary evaporator inlet line.
- Discard the Thermostatic Expansion Valve (TXV) filter.
12. To install, reverse the removal procedure.
- Install new O-ring seals.
- Install a new TXV filter.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
13. Evacuate, leak test and charge the refrigerant system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1455
Hose/Line HVAC: Service and Repair
Compressor To Condenser Discharge Line
Compressor to Condenser Discharge Line - 4.0L SOHC
Removal and Installation
1. Recover the refrigerant.
2. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket.
- To install, tighten to 7 Nm (62 lb-in).
3. Remove the compressor discharge fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (133 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 compressor-to-condenser discharge line.
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1456
- Install a new gasket seal and O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
8. 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.
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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1457
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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1458
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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1459
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
Removal and Installation
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1460
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 - 4.0L SOHC
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1461
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Recover the refrigerant.
3. Remove the compressor suction fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (133 lb-in).
4. Release the brake booster vacuum hose clamp and disconnect the hose.
5. Remove the suction accumulator-to-compressor line bracket bolt at the dash panel.
- To install, tighten to 11 Nm (97 lb-in).
6. Remove the suction accumulator outlet fitting nut.
- To install, tighten to 8 Nm (71 lb-in).
7. Disconnect the auxiliary evaporator outlet line fitting (if equipped).
- Discard the O-ring seals.
8. Remove the suction accumulator-to-compressor line.
- Discard the O-ring seal.
9. To install, reverse the removal procedure.
- Install new O-ring seals and a new gasket seal.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
10. Evacuate, leak test and charge the refrigerant system.
Suction Accumulator To Evaporator Line
Suction Accumulator To Evaporator Line
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1462
Removal and Installation
All vehicles
1. Remove the suction accumulator. For additional information, refer to Suction Accumulator See:
Heating and Air Conditioning/Accumulator
HVAC/Service and Repair.
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.
4. Disconnect the evaporator outlet fitting.
- Discard the O-ring seals.
Vehicles with 4.0L engine
5. Disconnect the Evaporative Emission (EVAP) return line fitting at the intake manifold.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1463
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.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
Auxiliary Heater Outlet and Inlet Line - Front
Auxiliary Heater Outlet and Inlet Line - Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1464
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.
Auxiliary Heater Outlet and Inlet Line - Rear
Auxiliary Heater Outlet and Inlet Line - Rear
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1465
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Drain the engine coolant.
3. Remove the spare tire.
4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type retainers.
5. Remove the spare tire carrier.
6. Release the 2 rear auxiliary heater line front hose clamps and disconnect the hoses.
7. Release the 2 rear auxiliary heater line rear hose clamps and disconnect the hoses.
8. Remove the 2 auxiliary line bracket nuts.
- 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line > Page 1466
12. To install, reverse the removal procedure.
13. Fill the engine cooling system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
NOTE: 4.6L engine shown, 4.0L engine similar.
Removal
NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Page 1470
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the power steering pump pulley. For additional information, refer to Power Steering
Pump Pulley - 4.0L See: Steering and
Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Power Steering
Pump Pulley or Power Steering Pump Pulley - 4.6L See: Steering and Suspension/Steering/Power
Steering/Power Steering Pump/Service and Repair/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.
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: A new Teflon(R) seal must be installed.
Using the Teflon(R) Seal Installer Set, 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 (97 lb-in).
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 (106 lb-in).
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. For additional information, refer to Power Steering Pump
Pulley - 4.0L See: Steering and
Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Power Steering
Pump Pulley or Power Steering Pump Pulley - 4.6L See: Steering and Suspension/Steering/Power
Steering/Power Steering Pump/Service and Repair/Power Steering Pump Pulley.
9. Fill the power steering system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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-C Ford Specification
......................................................................................................................................................
WSS-M6C62-A or WSS-M6C65-A1.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications
Coolant: Specifications
Engine Coolant
...................................................................................................................................................
Motorcraft Premium Gold Engine Coolant Note: Add the coolant type originally equipped in your
vehicle.
Ford Part Number ................................................................................................................................
................................................................... VC-7-B Ford Specification ...............................................
.....................................................................................................................................
WSS-M97B51-A1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
Automatic Tranmission Fluid Capacity
5R55 ....................................................................................................................................................
............................................... 11.2 Quarts ( 1067 L )
6R80 ....................................................................................................................................................
................................................ 11.2 Quarts ( 10.6 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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications > Page 1482
Fluid - A/T: Fluid Type Specifications
5R55S ..................................................................................................................................................
................................... Motorcraft MERCON V ATF
6R80 ....................................................................................................................................................
.................................. Motorcraft MERCON SP ATF
Use of a duel usage fluid in an automatic transmission requiring MERCON V may cause
transmission damage. Use of any fluid other than the recommended fluid may cause transmission
damage. Refer to scheduled maintenance information to determine the correct service interval.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S
Fluid - A/T: Service and Repair 5R55S
Transmission Fluid Level Check
Transmission Fluid Level Check
Transmission Fluid Fill Reference
NOTE: Left side of case shown.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S >
Page 1485
1. Using the scan tool, monitor the Transmission Fluid Temperature (TFT).
2. Start the engine.
3. NOTE: Engine idle speed is approximately 650 rpm.
Run the engine until the TFT is between 27-49°C (80-120°F).
4. Move the 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.
8. Install the Fluid Level and Fill Plug Adapter into the pan.
9. NOTE: Prior to filling the Fluid Transporter/Evacuator/Injector with transmission fluid, make sure
that the canister is clean.
Fill the Fluid Transporter/Evacuator/Injector with transmission fluid.
10. Hang the Fluid Transporter/Evacuator/Injector under the vehicle. Position it upright and close to
the transmission.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S >
Page 1486
11. Connect the Fluid Transporter/Evacuator/Injector.
- 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 Rubber Tip Air Nozzle. Transmission fluid will
immediately start flowing out of the Fluid Transporter/Evacuator/Injector 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 Rubber Tip
Air Nozzle from the end of the hose.
14. Inspect the transmission fluid level in the Fluid Transporter/Evacuator/Injector. 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 Vacuum Pump Kit on the open end of the
vacuum/pressure hose on the Fluid Transporter/Evacuator/Injector
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 TFT 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.
17. Reinstall the small (center) transmission fluid level indicating plug.
- Tighten to 10 Nm (89 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S >
Page 1487
18. Check the operation of the transmission by moving the selector lever slowly through each gear,
stopping in each position and allowing the
transmission to engage.
Transmission Fluid Exchange
Transmission Fluid Exchange
NOTICE: Use transmission fluid specific for this transmission. Do not use any supplemental
transmission fluid additives or cleaning agents. The use of these products can cause internal
transmission components to fail, which will affect the operation of the transmission.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Use the Heavy-Duty Transmission and Power Steering Fluid X-Changer to change the fluid.
3. Connect the Heavy-Duty Transmission and Power Steering Fluid X-Changer to the transmission
fluid cooler tube after the transmission fluid
cooler on the return tube. This will help remove any foreign material trapped in the transmission
fluid coolers.
4. Perform the transmission fluid exchange using the Heavy-Duty Transmission and Power
Steering Fluid X-Changer. Follow the manufacturer's
instructions included with the machine.
5. Once the transmission fluid exchange is completed, disconnect the Heavy-Duty Transmission
and Power Steering Fluid X-Changer. Reconnect any
disconnected transmission fluid cooler tubes.
6. Using the scan tool with the engine running, check and make sure that the transmission is at
normal operating temperature 66-77°C (150-170°F).
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.
Transmission Fluid Drain and Refill
Transmission Fluid Drain and Refill
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S >
Page 1488
Fluid Fill Reference
NOTE: Left side of case shown.
Draining
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S >
Page 1489
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 transmission fluid to drain.
Refill
1. Install the transmission fluid drain plug.
- Tighten to 26 Nm (19 lb-ft).
2. Hold the larger transmission fluid drain plug with a wrench and remove the small (center)
transmission fluid level indicating plug.
3. Install the Fluid Level and Fill Plug Adapter into the transmission fluid pan.
4. NOTE: Prior to filling the Fluid Transporter/Evacuator/Injector with transmission fluid, make sure
that the canister is clean.
Fill the Fluid Transporter/Evacuator/Injector with transmission fluid.
5. Hang the Fluid Transporter/Evacuator/Injector under the vehicle, upright and close to the
transmission.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S >
Page 1490
6. Connect the Fluid Transporter/Evacuator/Injector.
- 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
Rubber Tip Air Nozzle. Transmission fluid will
immediately start flowing out of the Fluid Transporter/Evacuator/Injector into the transmission fluid
pan.
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 Rubber Tip 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 (TFT) is
between 27°C-49°C (80°F-120°F).
10. Inspect the transmission fluid level in the Fluid Transporter/Evacuator/Injector. 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 Kit on the open end of the
vacuum/pressure hose on the Fluid
Transporter/Evacuator/Injector 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S >
Page 1491
13. Reinstall the small (center) transmission fluid level indicating plug.
- Tighten to 10 Nm (89 lb-in).
Transmission Fluid Cooler Backflushing and Cleaning
Transmission Fluid Cooler Backflushing and Cleaning
NOTICE: 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.
NOTICE: 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 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 tubes, connect 2 additional rubber
hoses to the transmission end of the steel
transmission cooler tubes as described. 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 tubes (blow air into the transmission cooler
return tube) until all the fluid is removed.
7. Remove the rubber return hose from the remaining steel cooler tube.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S >
Page 1492
Fluid - A/T: Service and Repair 6R80
Transmission Fluid Drain and Refill
Transmission Fluid Drain and Refill
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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S >
Page 1493
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.
5. Install the transmission fluid pan and tighten the bolts in a crisscross pattern.
- Tighten to 12 Nm (106 lb-in).
Transmission Fluid Refill
NOTICE: 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.
NOTICE: The vehicle should not be driven if the transmission fluid level is low as internal failure
could result.
NOTICE: The transmission fluid fill plug is located near the exhaust system. The exhaust will be
extremely hot during this procedure.
NOTICE: 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 transmission fluid to the transmission is an initial fill enabling you to start
the engine.
- The cold 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 fill 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 transmission fluid added to the transmission
as an initial fill if:
- the transmission has been overhauled.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S >
Page 1494
- a new mechatronic assembly has been installed.
- the transmission fluid pan or transmission fluid filter have been removed.
Using the Transmission Fluid Fill Tube, add 3.3L (3.5 qt) of transmission fluid to the transmission
through the transmission fluid fill hole. For additional information, refer to Adding Additional
Transmission Fluid in this procedure.
2. Check the transmission fluid level cold.
- The vehicle is safe to drive if the transmission fluid is in the cold level range 32°C-43°C
(90°F-110°F).
- Using the scan tool and with the engine running, place the selector lever in each gear position
and hold approximately 5 seconds. Place the 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.
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 transmission fluid to the cold level location as shown in the illustration.
6. Install the transmission fluid fill plug.
- Tighten to 35 Nm (26 lb-ft).
7. While driving the vehicle, use the scan tool to verify that the Transmission Fluid Temperature
(TFT) 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 transmission fluid cooling system. With the engine idling (600-750 rpm) in PARK, verify that the TFT 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S >
Page 1495
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.
11. Using the scan tool verify that the TFT 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 Transmission Fluid Fill Tube into the transmission fluid fill hole.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S >
Page 1496
2. Fill the Transporter Fluid Evacuator/Injector with approximately 0.47L (1 pt) of transmission fluid.
3. Hang the Transporter Fluid Evacuator/Injector under the vehicle, upright and close to the
transmission.
4. Connect the Transporter Fluid Evacuator/Injector and Transmission Fluid Fill Tube.
- Connect the open end of the fluid hose from the Transporter Fluid Evacuator/Injector onto the
Transmission Fluid Fill Tube from the transmission case.
5. Use a Rubber Tip Air Nozzle to apply a maximum of 206.85 kPa (30 psi) to the open end of the
vacuum/pressure hose from the Transporter Fluid
Evacuator/Injector. Transmission fluid will immediately start flowing out of the Transporter Fluid
Evacuator/Injector 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S >
Page 1497
7. Using the scan tool, verify that the TFT 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).
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
Transporter Fluid Evacuator/Injector and the
Vacuum Pump Kit to extract any excessive transmission fluid.
2. Using the scan tool, verify that the TFT 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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S >
Page 1498
Transmission Fluid Exchange
Transmission Fluid Exchange
NOTICE: Use transmission fluid specific for this transmission. Do not use any supplemental
transmission fluid additives or cleaning agents. The use of these products can cause internal
transmission components to fail, which will affect the operation of the transmission.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Use the Heavy-Duty Transmission and Power Steering Fluid X-Changer to change the fluid.
3. Connect the Heavy-Duty Transmission and Power Steering Fluid X-Changer to the transmission
fluid cooler tube after the transmission fluid
cooler on the return tube. This will help remove any foreign material trapped in the transmission
fluid coolers.
4. Perform the transmission fluid exchange using the Heavy-Duty Transmission and Power
Steering Fluid X-Changer. Follow the manufacturer's
instructions included with the machine.
5. Once the transmission fluid exchange is completed, disconnect the Heavy-Duty Transmission
and Power Steering Fluid X-Changer. Reconnect any
disconnected transmission fluid cooler tubes.
6. Using the scan tool with the engine running, check and make sure that the transmission is at
normal operating temperature 66-77°C (150-170°F).
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.
Transmission Fluid Level Check
Transmission Fluid Level Check
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S >
Page 1499
NOTICE: The vehicle should not be driven if the transmission fluid level is low as internal failure
could result.
NOTICE: 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 or transmission fluid cooler tubes has
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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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6. Using the scan tool, verify that the Transmission Fluid Temperature (TFT) 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. For additional information, refer to Transmission Fluid Drain and Refill See: Transmission
and Drivetrain/Automatic Transmission/Transaxle/Service and
Repair/Procedures/6R80/Transmission Fluid Drain and Refill.
Install the transmission fluid fill plug. Tighten to 35 Nm (26 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications
Fluid - Differential: Specifications
Motorcraft SAE 75W-140 High Performance Synthetic Rear Axle Lubricant Ford Part Number ........
..............................................................................................................................................................
................. XY-75W140-QL Ford Specification ...................................................................................
................................................................................................... WSL-M2C192-A
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine Oil
With Filter ............................................................................................................................................
............................................................. 4.7L (5.0 Qt)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications > Page 1508
Engine Oil: Fluid Type Specifications
Engine Oil
U.S. .........................................................................................................................................
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil Canada
....................................................................................................................................................
Motorcraft SAE 5W-30 Super Premium Motor Oil
Note: Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only have the
API Certification mark and meet the requirements of Ford Specification WSS-M2C929-A.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Capacity Specifications
Power Steering Fluid: Capacity Specifications
Fill between the MIN and MAX lines on reservoir
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Capacity Specifications > Page 1513
Power Steering Fluid: Fluid Type 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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Item..............................................................................................................................R-134a
Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification...........................................
......................................................................................................................................................WS
H-M17B19-A Fill
Capacity...........................................................................................................................(0.77 kg) (27
oz) (1.7 lb) (vehicles without auxiliary systems)
Item..............................................................................................................................R-134a
Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification...........................................
......................................................................................................................................................WS
H-M17B19-A Fill
Capacity...................................................................................................................(1.25 kg) (44 oz)
(2.75 lb) (vehicles with auxiliary climate control)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 1518
Refrigerant: Fluid Type Specifications
Item..............................................................................................................................R-134a
Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification...........................................
......................................................................................................................................................WS
H-M17B19-A Fill
Capacity...........................................................................................................................(0.77 kg) (27
oz) (1.7 lb) (vehicles without auxiliary systems)
Item..............................................................................................................................R-134a
Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification...........................................
......................................................................................................................................................WS
H-M17B19-A Fill
Capacity...................................................................................................................(1.25 kg) (44 oz)
(2.75 lb) (vehicles with auxiliary climate control)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1519
Refrigerant: Testing and Inspection
Refrigerant Identification Testing
Refrigerant Identification
1. NOTE: A Refrigerant Blend Identifier with Printer must be used to identify gas samples taken
directly from the refrigeration system or storage
containers prior to recovering or charging the refrigerant system.
Follow the instructions included with the Refrigerant Blend Identifier with Printer to obtain the
sample for testing.
2. The Refrigerant Blend Identifier with Printer will display one of the following:
- If the purity level of R-134a is 98% or greater by weight, the green PASS LED will light. The
weight concentrations of R-134a, R-12, R-22, hydrocarbons and air will be displayed on the digital
display.
- If refrigerant R-134a does not meet the 98% purity level, the red FAIL LED will light and an alarm
will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22
and hydrocarbons will be displayed on the digital display.
- If hydrocarbon concentrations are 2% or greater by weight, the red FAIL LED will light,
"Hydrocarbon High" will be displayed on the digital display, and an alarm will sound alerting the
user of potential hazards. The weight concentrations of R-134a, R-12, R-22 and hydrocarbons will
also be displayed on the digital display.
3. The percentage of air contained in the sample will be displayed if the R-134a content is 98% or
greater. The Refrigerant Blend Identifier with
Printer eliminates the effect of air when determining the refrigerant sample content because air is
not considered a contaminant, although air can affect A/C system performance. When the
Refrigerant Blend Identifier with Printer has determined that a refrigerant source is pure (R-134a is
98% or greater by weight) and air concentration levels are 2% or greater by weight, the scan tool
will prompt the user if an air purge is desired.
4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the
refrigerant is indeed contaminated.
Contaminated Refrigerant Handling
NOTICE: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a
recovery/recycling equipment. Recovery of contaminated refrigerant will contaminate the recovered
refrigerant supply and may damage the recovery/recycling equipment.
NOTE: A new suction accumulator or receiver/drier must be installed as directed by the A/C system
flushing procedure.
1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant only.
- If this equipment is not available, contact an A/C service facility in the area with the correct
equipment to carry out this service.
2. Determine and correct the cause of the customers initial concern.
3. Flush the A/C system.
4. Dispose of the contaminated refrigerant in accordance with all federal, state and local
regulations.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air
Conditioning (A/C) System Recovery, Evacuation and Charging
Refrigerant: Service and Repair Air Conditioning (A/C) System Recovery, Evacuation and Charging
Air Conditioning (A/C) System Recovery, Evacuation and Charging
Refrigerant System Recovery
NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any
vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If
the vehicle's A/C refrigerant is contaminated, refer the customer to the service
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air
Conditioning (A/C) System Recovery, Evacuation and Charging > Page 1522
facility that carried out the last A/C service. If the customer wishes to pay the additional cost, use
the A/C recovery equipment that is designated for recovering contaminated A/C refrigerant. All
contaminated A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow
the equipment manufacturer procedures and instructions.
NOTE: Ford Motor Company recommends the use of R-134a refrigerant management equipment
that meets the requirements of the SAE J2788 standard.
NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to
carry out recovery. If a R-134a Refrigerant Management Machine is not available, refrigerant
system recovery may be accomplished using a separate recovery station.
NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in
vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is
necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly
basis to verify that no leaks are present.
1. Prior to recovering, the purity of the refrigerant must be verified. For additional information, refer
to Refrigerant Identification Testing See:
Heating and Air Conditioning/Testing and Inspection/Component Tests and General
Diagnostics/Refrigerant Identification Testing.
2. Connect a R-134a Refrigerant Management Machine to the low- and high-pressure service
gauge port valves following the operating instructions
provided by the equipment manufacturer.
3. Recover the refrigerant from the system following the operating instructions provided by the
equipment manufacturer. Note the amount of oil
removed during the refrigerant recovery (if any). Add that same amount back into the system once
repairs are complete.
4. Once the R-134a Refrigerant Management Machine has recovered the refrigerant, switch OFF
the power supply.
5. Allow the system to set for about 2 minutes, and observe the system vacuum reading. If the
vacuum is not lost, disconnect the recovery equipment.
6. If the system does lose vacuum, repeat Steps 3 through 5 until the vacuum level remains stable
for 2 minutes.
7. Carry out the required repairs.
Refrigerant System Evacuation Using a R-134a Refrigerant Management Machine
NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to
carry out recovery, evacuation and charging of the refrigerant system. If a R-134a Refrigerant
Management Machine is not available, evacuation may be accomplished using a separate Vacuum
Pump and R-134a Manifold Gauge Set.
NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in
vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is
necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly
basis to verify that no leaks are present.
1. Connect a R-134a Refrigerant Management Machine to the low- and high-pressure service
gauge port valves following the operating instructions
provided by the equipment manufacturer.
2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of
vacuum and as close to 101.1 kPa (30 in-Hg) as possible.
Continue to operate the Vacuum Pump for a minimum of 45 minutes.
3. Turn OFF the Vacuum Pump. Observe the low-pressure gauge for 5 minutes to make sure that
the system vacuum is held. If vacuum is not held for
5 minutes, leak test the system, repair the leak and evacuate the system again.
Refrigerant System Evacuation Using a R-134a Manifold Gauge Set and Vacuum Pump
NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to
carry out evacuation of the refrigerant system. If a R-134a Refrigerant Management Machine is not
available, refrigerant system evacuation may be accomplished using a separate Vacuum Pump
and R-134a Manifold Gauge Set.
NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in
vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is
necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly
basis to verify that no leaks are present.
1. Connect the R-134a Manifold Gauge Set to the low-side and high-side service gauge port
valves.
2. Connect the center (yellow) hose from the R-134a Manifold Gauge Set to the suction port on the
Vacuum Pump.
3. Open all valves on the R-134a Manifold Gauge Set and both service gauge port valves.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air
Conditioning (A/C) System Recovery, Evacuation and Charging > Page 1523
4. Turn on the Vacuum Pump and evacuate the system until the low-pressure gauge reads at least
99.4 kPa (29.5 in-Hg) of vacuum and as close to
101.1 kPa (30 in-Hg) as possible. Continue to operate the Vacuum Pump for a minimum of 45
minutes.
5. Close the high-side and low-side valves on the R-134a Manifold Gauge Set (not the service
gauge port valves) and turn OFF the Vacuum Pump.
6. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If
vacuum is not held for 5 minutes, leak test the
system, repair the leak and evacuate the system again.
Refrigerant System Charging Using a R-134a Refrigerant Management Machine
NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to
carry out charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not
available, refrigerant system charging may be accomplished using a separate Automatic
Refrigerant Charging Meter and R-134a Manifold Gauge Set.
NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may
be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all
refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks
are present.
1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional
information, refer to Refrigerant Oil Adding See:
Heating and Air Conditioning/Service and Repair/Refrigerant Oil Adding.
2. Connect a R-134a Refrigerant Management Machine to the low-side and high-side service
gauge port valves following the operating instructions
provided by the equipment manufacturer.
3. Set the refrigerant charge amount, and charge the refrigerant system following the instructions
provided by the equipment manufacturer.
Refrigerant System Charging Using a R-134a Manifold Gauge Set and Automatic Refrigerant
Charging Meter
NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to
carry out charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not
available, refrigerant system charging may be accomplished using a separate Automatic
Refrigerant Charging Meter and R-134a Manifold Gauge Set.
NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may
be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all
refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks
are present.
1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional
information, refer to Refrigerant Oil Adding See:
Heating and Air Conditioning/Service and Repair/Refrigerant Oil Adding.
2. Assemble the R-134a Manifold Gauge Set, Automatic Refrigerant Charging Meter and R-134a
supply tank following the Automatic Refrigerant
Charging Meter operating instructions.
3. Charge the refrigerant system following the Automatic Refrigerant Charging Meter operating
instructions.
4. If the refrigerant flow stops before the refrigerant charge is complete, start the engine, select
MAX A/C operation and allow the refrigerant charge
to complete.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air
Conditioning (A/C) System Recovery, Evacuation and Charging > Page 1524
Refrigerant: Service and Repair Refrigerant System Filtering Following Air Conditioning (A/C)
Compressor Installation
Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation
WARNING: Use extreme care and observe all safety and service precautions related to the use of
refrigerants as outlined on refrigerant tank and on recovery and charging equipment. Failure to
follow these instructions may result in serious personal injury.
NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any
vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If
the vehicle's A/C refrigerant is contaminated, refer the customer to the service facility that carried
out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery
equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C
refrigerant must be disposed of as hazardous waste. For all equipment, follow the equipment
manufacturer's procedures and instructions.
NOTICE: On vehicles being serviced for an internal compressor or desiccant failure, a new suction
accumulator or receiver/drier, Thermostatic Expansion Valve (TXV) or evaporator core orifice and
any hoses containing mufflers must be installed prior to filtering the Air Conditioning (A/C) system.
Internal plumbing of these devices makes it impossible to correctly remove any foreign material.
These components are typically discarded after A/C system contamination. Hoses without mufflers
can normally be reused unless they are clogged with foreign material. The filter is intended for use
on one vehicle only.
1. Orient the filter inlet toward the A/C condenser core.
2. NOTICE: The flexible extension adapters included in the A/C Flush Adapter Kit are designed for
low-pressure flushing and are not
designed for use with a charged refrigerant system. Do not make the condenser fitting connections
using the flexible extension adapters or damage to the adapters and loss of refrigerant will occur.
NOTE: The F8VZ-19E773-AB pancake filter is not permanently installed and will be removed at the
end of this procedure.
Disconnect the condenser outlet fitting and temporarily install the pancake filter between the 2
halves of the fitting.
- Use flexible refrigerant hose of 17,238 kPa (2,500 psi) burst rating.
- Make the connections using the correct adapters from the A/C Flush Adapter Kit and/or A/C Flush
and Purge Fitting Kit.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air
Conditioning (A/C) System Recovery, Evacuation and Charging > Page 1525
3. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional
information, refer to Refrigerant Oil Adding See:
Heating and Air Conditioning/Service and Repair/Refrigerant Oil Adding.
4. Evacuate and charge the refrigerant system. For additional information, refer to Air Conditioning
(A/C) System Recovery, Evacuation and
Charging See: Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System
Recovery, Evacuation and Charging.
5. Check all refrigerant system hoses, lines and the position of the newly installed filters to be sure
they do not interfere with other engine
compartment components. If necessary, use tie straps to make adjustments.
6. Provide adequate airflow to the front of the vehicle (with a fan, if necessary). Select A/C
operation and set the blower motor speed to maximum.
Start the engine and let it idle briefly. Make sure the A/C system is operating correctly.
7. Gradually bring the engine up to 1,200 rpm by running it at lower rpms for short periods (first at
800 rpm, then at 1,000 rpm). Set the engine at
1,200 rpm and run it for one hour with the A/C system operating.
8. Stop the engine.
9. Recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System
Recovery, Evacuation and Charging See: Heating and
Air Conditioning/Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and
Charging.
10. Remove the adapters, flexible hoses and pancake filter from between the condenser and the
condenser to evaporator tube.
11. Discard the pancake filter. It can be used one time only.
12. Reconnect the condenser outlet fitting.
13. Evacuate, charge and leak-test the refrigerant system. For additional information, refer to Air
Conditioning (A/C) System Recovery, Evacuation
and Charging See: Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System
Recovery, Evacuation and Charging.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair
Refrigerant Oil: Service and Repair
Refrigerant Oil Adding
Refrigerant Oil Adding
NOTE: During normal A/C operation, oil is circulated through the system with the refrigerant, and a
small amount is retained in each component. If certain components of the system are removed,
some of the PAG oil will go with the component. To maintain the original total oil charge, it is
necessary to compensate for the oil lost by adding oil to the system with the new part.
1. Refer to the chart below for refrigerant oil adding amounts and methods of installation.
a If an excessive amount of PAG oil is lost due to a hose rupture/separation or other damage, the
total system PAG oil capacity must be added.
b The amount specified may be used for one or multiple O-ring leak repairs. Do not multiply the
PAG oil amount by the number of O-ring leaks being
repaired.
Adding Refrigerant Oil After A/C Compressor Replacement
Service A/C compressors shipped without clutch and pulley
1. Rotate the A/C compressor shaft 6 to 8 revolutions while collecting oil in a clean measuring
device.
- If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 oz), pour the
same amount plus 30 ml (1 oz) of clean PAG Refrigerant Compressor Oil (R-134a Systems)
(YN-12-D) WSH M1C231-B or equivalent into the new A/C compressor.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Page
1529
- If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 oz),
pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) or
equivalent into the new A/C compressor.
- If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 oz), pour
85 ml (3 oz) of clean A/C Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new
A/C compressor.
Service A/C compressors shipped with clutch and pulley
2. Rotate the old A/C compressor shaft 6 to 8 revolutions while collecting oil in a clean measuring
device.
- If the amount of oil drained from the old A/C compressor is less than 89 ml (3 oz), remove 118 ml
(4 oz) from the new A/C compressor.
- If the amount of oil drained from the old A/C compressor is 89 ml (3 oz), remove 89 ml (3 oz) from
the new A/C compressor.
- If the amount of oil drained from the old A/C compressor is 118 ml (4 oz), remove 59 ml (2 oz)
from the new A/C compressor.
- If the amount of oil drained from the old A/C compressor is 148 ml (5 oz), remove 29 ml (1 oz)
from the new A/C compressor.
- If the amount of oil drained from the old A/C compressor is greater than 148 ml (5 oz), remove 0
ml (0 oz) from the new A/C compressor.
Adding Refrigerant Oil After New Suction Accumulator or Receiver/Drier Replacement
NOTE: This refrigerant oil adding method is to be used when a new suction accumulator or
receiver drier only has been installed. If a new A/C compressor and evaporator core orifice or TXV
have also been installed due to system contamination, refer to the appropriate heading.
1. Drill one 12.7 mm (1/2 in) hole in the old suction accumulator or receiver/drier cylinder and drain
the oil into a clean measuring cup.
2. Add the same quantity of new PAG oil, plus the amount collected during refrigerant recovery and
60 ml (2 fl oz).
Adding Refrigerant Oil After Multiple Component Replacement After A/C System Contamination
NOTE: This refrigerant oil adding method is to be used when a new A/C compressor, suction
accumulator or receiver drier and evaporator core orifice or TXV have been installed due to system
contamination and the A/C system has been flushed.
NOTE: Service A/C compressors are shipped without refrigerant oil.
1. Add 60 ml (2 fl oz) directly to the new A/C compressor suction port.
2. Inject the total vehicle PAG oil capacity minus 60 ml (2 fl oz) to the low-side service port during
system charging. For the total PAG oil capacity
specification, refer to the Specifications table.
Oil Injection Using a Dye/Lubricant Injector
NOTE: If fluorescent leak detection dye is also to be added during A/C charging, the dye may be
added to the dye/lubricant injector, from the R-134a Loop/Add On Injector Kit-Set, along with the
PAG oil.
1. Evacuate the refrigerant system. For additional information, refer to Air Conditioning (A/C)
System Recovery, Evacuation and Charging See:
Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System Recovery,
Evacuation and Charging.
2. Assemble the dye/lubricant injector and the correct adapters from the R-134a Loop/Add On
Injector Kit-Set to match the amount of refrigerant
compressor oil to be injected.
3. Verify that all the valves on the dye/lubricant injector are closed.
4. Fill the dye/lubricant injector with the correct amount of clean, new PAG oil.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Page
1530
5. Install the dye/lubricant injector between the low-side service gauge port valve and the
refrigerant service station or manifold gauge set.
6. Open all valves and charge the refrigerant system. For additional information, refer to Air
Conditioning (A/C) System Recovery, Evacuation and
Charging See: Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System
Recovery, Evacuation and Charging.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component
Bleeding
Brake Bleeding: Service and Repair Component Bleeding
Master Cylinder
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
NOTE: When a new brake master cylinder is installed, or the system is 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.
3. Fill the brake master cylinder reservoir with clean, specified brake fluid.
4. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air
bubbles.
5. Remove the short brake tubes and install the brake outlet tubes.
6. 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,
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component
Bleeding > Page 1535
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 brake tube fittings to specifications. For additional information, refer to
Specifications.
7. Bleed the brake system, refer to Brake System Bleeding See: Brake System Bleeding.
Brake Caliper
Component Bleeding
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
1. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was
disconnected or installed new.
Remove the 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 at least 2 times 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.
4. Remove the rubber hose and tighten the bleeder screw to specifications. For additional
information, refer to Specifications.
- Install the bleeder screw cap.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component
Bleeding > Page 1536
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component
Bleeding > Page 1537
Brake Bleeding: Service and Repair Brake System Bleeding
Brake System Bleeding
Pressure
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any
components upstream of the HCU are installed new.
NOTE: Pressure bleeding the brake system is preferred to manual bleeding.
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: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the equipment 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: Make sure the bleeder tank contains enough clean, specified brake fluid to complete the
bleeding operation.
Remove the RH rear 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.
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Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component
Bleeding > Page 1538
4. Open the valve on the bleeder tank.
- Set pressure to 207-345 kPa (30-50 psi).
5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then
tighten the RH rear bleeder screw and remove the
rubber hose. Tighten to specifications. For additional information, refer to Specifications.
- Install the bleeder screw cap.
6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front
bleeder screw ending with the LH front bleeder
screw.
7. Release the bleeder tank pressure and close the bleeder tank valve. Remove the tank hose from
the adapter and remove the adapter from the brake
fluid reservoir.
Manual
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any
components upstream of the HCU are installed new.
NOTE: Pressure bleeding the brake system is preferred to manual bleeding.
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. Remove the bleeder screw cap and place a box-end wrench on the RH rear bleeder screw.
Attach a rubber drain hose to the RH rear bleeder screw
and submerge the free end of the hose in a container partially filled with clean, specified brake
fluid.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component
Bleeding > Page 1539
3. Have an assistant pump the brake pedal at least 3 times and then hold firm pressure on the
brake pedal.
4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the
RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
5. Remove the rubber hose and tighten the bleeder screw to specifications. For additional
information, refer to Specifications.
- Install the bleeder screw cap.
6. Repeat Steps 2 through 5 for the LH rear, RH front and LH front bleeder screws in this order.
Hydraulic Control Unit (HCU)
NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any
components upstream of the HCU are installed new.
NOTE: Pressure bleeding the brake system is preferred to manual bleeding.
1. Follow the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system.
2. Connect the scan tool and follow the ABS Service Bleed instructions.
3. Repeat the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Depowering Procedure
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
may result in serious personal injury.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
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(R) and
cause serious personal injury or death.
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (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 RCM fuse 17 (10A) from the SJB.
For additional information, refer to the Wiring Diagram.
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 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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1544
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 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 an 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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1545
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Deactivation and Reactivation
Supplemental Restraint System (SRS) Deactivation and Reactivation
Deactivation
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
may result in serious personal injury.
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.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
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.
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
All vehicles
1. Turn all vehicle accessories OFF.
2. Turn the ignition switch OFF.
3. At the Smart Junction Box (SJB), located below the LH side of the instrument panel, remove the
cover and RCM fuse 17 (10A) from the SJB. For
additional information, refer to the Wiring Diagrams.
4. Turn the ignition switch 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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1546
7. Remove the 2 driver air bag module bolts (1 shown).
8. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag
module.
9. Open and lower the glove compartment door.
10. Detach the wiring retainer, remove the 4 bolts and passenger air bag module heat shield.
11. NOTE: The canister vent and adaptive tether do not require deactivation.
Disconnect the LH side passenger air bag module electrical connector.
12. Under the rear of the passenger seat, detach the passenger seat side air bag module electrical
connector from the seat track bracket. Disengage the
passenger seat side air bag module electrical connector locking clip, release the tab and
disconnect the passenger seat side air bag module electrical connector.
Explorer and Mountaineer vehicles
13. Release and position aside the passenger side C-pillar trim panel.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1547
14. Disconnect the passenger side safety canopy module electrical connector.
15. Release and position aside the driver side C-pillar trim panel.
16. Disconnect the driver side safety canopy module electrical connector.
Explorer Sport Trac vehicles
17. Remove the driver and passenger side upper C-pillar trim panels.
18. Disconnect the passenger side safety canopy module electrical connector.
19. Disconnect the driver side safety canopy module electrical connector.
All vehicles
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1548
20. Under driver seat, the rear of the slide and disengage the driver seat side air bag module
electrical connector locking clip, release the tab and
disconnect the driver seat side air bag module electrical connector.
21. Install the RCM fuse 17 (10A) to the SJB.
22. 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. Connect the driver seat side air bag module electrical connector and engage the seat side air
bag electrical connector locking clip.
Explorer Sport Trac vehicles
4. Connect the driver side safety canopy module electrical connector.
5. Connect the passenger side safety canopy module electrical connector.
6. Install the driver and passenger upper C-pillar trim panels.
Explorer and Mountaineer vehicles
7. Connect the driver side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1549
8. Install the driver side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
9. Connect the passenger side safety canopy module electrical connector.
10. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles
11. Connect the passenger seat side air bag module electrical connector and engage the seat side
air bag electrical connector locking clip. Attach the
passenger seat side air bag module electrical connector to the seat track bracket.
12. Connect the LH side passenger air bag module electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1550
13. Install the passenger air bag module heat shield and 4 bolts. Attach the wiring retainer.
14. NOTICE: 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.
15. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
16. Turn the ignition switch from OFF to ON.
17. Install RCM fuse 17 (10A) to the SJB and install the cover.
18. 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.
19. 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 an 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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Locations
Circuit Breaker: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Locations > Page 1555
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Locations > Page 1556
Circuit Breaker: Application and ID
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Locations > Page 1557
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1562
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1563
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1564
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1565
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1566
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1567
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1568
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1569
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1570
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1571
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Fuse: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1574
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1575
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1576
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1577
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1578
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1579
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1580
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1581
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1582
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1583
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Battery Junction Box (BJB)
Fuse Block: Locations Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Battery Junction Box (BJB) > Page 1588
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Battery Junction Box (BJB) > Page 1589
Fuse Block: Locations Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Battery Junction Box (BJB) > Page 1590
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Battery Junction Box (BJB) > Page 1591
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Battery Junction Box (BJB) > Page 1592
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Battery Junction Box (BJB) > Page 1593
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Battery Junction Box (BJB) > Page 1594
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1597
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1598
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1599
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1600
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
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1601
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery 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 loose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1602
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1603
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1604
Symbols (Part 4)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1605
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1606
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.
Defective insulation stripping
1 = Proper crimp
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1607
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1608
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1609
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1610
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1611
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.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1612
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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1613
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1614
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1615
Fuse Block: Connector Views
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1616
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1617
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1618
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1619
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1620
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1621
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Battery Junction Box (BJB)
Relay Box: Locations Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Battery Junction Box (BJB) > Page 1626
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Battery Junction Box (BJB) > Page 1627
Relay Box: Locations Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Battery Junction Box (BJB) > Page 1628
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Battery Junction Box (BJB) > Page 1629
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Battery Junction Box (BJB) > Page 1630
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Battery Junction Box (BJB) > Page 1631
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Battery Junction Box (BJB) > Page 1632
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB)
Relay Box: Diagrams Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1635
Relay Box: Diagrams Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1636
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1637
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1638
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1639
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1640
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Battery Junction Box (BJB)
Relay Box: Application and ID Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Battery Junction Box (BJB) > Page 1643
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Battery Junction Box (BJB) > Page 1644
Relay Box: Application and ID Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Battery Junction Box (BJB) > Page 1645
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Service and Repair > Oil Life Reset and Start Value - With Message Center
Maintenance Required Lamp/Indicator: Service and Repair Oil Life Reset and Start Value - With
Message Center
Message Center Configuration
Oil Life Reset And Start Value - With Message Center
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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Service and Repair > Oil Life Reset and Start Value - With Message Center > Page 1651
Maintenance Required Lamp/Indicator: Service and Repair Oil Life Reset and Start Value - Without
Message Center
Message Center Configuration
Oil Life Reset And Start Value - Without Message Center
NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180
days.
NOTE: All message center functions are carried out using the single stem reset button in the
Instrument Cluster (IC).
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 (V6-4.0L (2009))
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)
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 four 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 three
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/No Diagnostic
Trouble Codes (DTCs) Present Symptom Chart Index.
- 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 ignition in the RUN position (engine not running) if
DTC P1000 is set.
CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
WARNING: 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.
WARNING: 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.
WARNING: 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.
WARNING: 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.
NOTICE: 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.
NOTICE: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on
lift without first checking for possible interference.
NOTICE: 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.
NOTICE: 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
Lifting Points
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and
Operation > Page 1662
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 See: Tire Monitoring System/Testing
and Inspection/Programming and Relearning.
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire
Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and
appliance operation, cellular telephones, remote transmitters, power inverters and portable
entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to
activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not
respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate
the same sensor again.
NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not
recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and
the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire
procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for
front and rear tires, tire rotation will not affect the system.
1. Turn the ignition switch to the OFF position, then press and release the brake pedal.
2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
3. Press and release the brake pedal.
4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
- The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully. If equipped, the message center will display TRAIN LF TIRE.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in
place 180 degrees from the valve stem.
Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from
the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The
horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1668
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall opposite (180 degrees) from the
valve stem and press and release the test button to train the RF tire pressure sensor.
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 identifiers 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 carry out
the SJB On-Demand Self Test.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1669
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 Tire Pressure Monitor 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 Tire Pressure Monitor 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. See: Tire Monitoring System/Testing and Inspection/Symptom
Related Diagnostic Procedures
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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. NOTICE: 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. For additional information, refer to Wheel and Tire See: Service
and Repair/Overhaul.
2. NOTICE: 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.
3. NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1672
4. Remove the sensor.
Assembly
1. NOTICE: 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.
3. NOTICE: 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. For additional information, refer to Wheel and Tire See: Service and
Repair/Overhaul.
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 See: Tire Monitoring System/Testing and Inspection/Monitors,
Trips, Drive Cycles and Readiness Codes.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1673
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
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 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 See: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1674
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 in) 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. NOTICE: 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.
Using wheel and tire cleaner, clean the area where the sensor and cradle are to be installed.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1675
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. NOTICE: 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 in) away from the sensor and tighten the worm gear.
- Tighten to 3 Nm (27 lb-in).
6. NOTICE: 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. For additional information, refer to Wheel and Tire. See: Service and
Repair/Overhaul
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. See: Tire Monitoring System/Testing and Inspection/Monitors,
Trips, Drive Cycles and Readiness Codes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 See: Testing and
Inspection/Programming and Relearning.
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire
Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and
appliance operation, cellular telephones, remote transmitters, power inverters and portable
entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to
activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not
respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate
the same sensor again.
NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not
recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and
the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire
procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for
front and rear tires, tire rotation will not affect the system.
1. Turn the ignition switch to the OFF position, then press and release the brake pedal.
2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
3. Press and release the brake pedal.
4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
- The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully. If equipped, the message center will display TRAIN LF TIRE.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in
place 180 degrees from the valve stem.
Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from
the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The
horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1681
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall opposite (180 degrees) from the
valve stem and press and release the test button to train the RF tire pressure sensor.
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 identifiers 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 carry out
the SJB On-Demand Self Test.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1682
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 Tire Pressure Monitor 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 Tire Pressure Monitor 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. See: Testing and Inspection/Symptom Related Diagnostic
Procedures
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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. NOTICE: 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. For additional information, refer to Wheel and Tire See: Service
and Repair/Overhaul.
2. NOTICE: 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.
3. NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1685
4. Remove the sensor.
Assembly
1. NOTICE: 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.
3. NOTICE: 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. For additional information, refer to Wheel and Tire See: Service and
Repair/Overhaul.
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 See: Testing and Inspection/Monitors, Trips, Drive Cycles and
Readiness Codes.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1686
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
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 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 See: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1687
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 in) 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. NOTICE: 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.
Using wheel and tire cleaner, clean the area where the sensor and cradle are to be installed.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1688
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. NOTICE: 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 in) away from the sensor and tighten the worm gear.
- Tighten to 3 Nm (27 lb-in).
6. NOTICE: 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. For additional information, refer to Wheel and Tire. See: Service and
Repair/Overhaul
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. See: Testing and Inspection/Monitors, Trips, Drive Cycles and
Readiness Codes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 1697
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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking
Wheels: Customer Interest Wheels - 17 Inch Polished Wheel Clearcoat Cracking
TSB 09-14-1
07/27/09
17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and
equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks
in the clear coat that look like spider webs.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Please review the illustrations of an affected wheel. (Figures 1 and 2)
2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04
for wheel removal and installation procedures
including tire pressure monitoring system (TPMS) sensor.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1702
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
091401A 2006-2010 Explorer, 0.6 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer
TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091401B 2006-2010 Explorer, 0.8 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401C 2006-2010 Explorer, 1.1 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To
Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401D 2006-2010 Explorer, 1.3 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 91
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 1708
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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat
Cracking
Wheels: All Technical Service Bulletins Wheels - 17 Inch Polished Wheel Clearcoat Cracking
TSB 09-14-1
07/27/09
17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and
equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks
in the clear coat that look like spider webs.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Please review the illustrations of an affected wheel. (Figures 1 and 2)
2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04
for wheel removal and installation procedures
including tire pressure monitoring system (TPMS) sensor.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 1713
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
091401A 2006-2010 Explorer, 0.6 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer
TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091401B 2006-2010 Explorer, 0.8 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401C 2006-2010 Explorer, 1.1 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To
Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401D 2006-2010 Explorer, 1.3 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 91
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Suspension
Wheel Bearing: Service and Repair Front Suspension
Wheel Bearing and Wheel Hub
Removal and Installation
NOTICE: 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. NOTICE: 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 the new bolts 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 (159 lb-in).
5. Remove the 3 bolts and the wheel bearing and wheel hub.
- Discard the bolts.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Suspension > Page 1718
- To install, tighten the new bolts to 122 Nm (90 lb-ft).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Suspension > Page 1719
Wheel Bearing: Service and Repair Rear Suspension
Wheel Bearing and Wheel Hub
Removal and Installation
NOTICE: 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. For additional information, refer to Wheel Knuckle See: Steering and
Suspension/Suspension/Rear Knuckle/Service
and Repair.
2. Remove the 3 brake disc shield bolts.
- To install, tighten to 8 Nm (71 lb-in).
3. Using the Bearing Puller and a suitable press, remove the wheel hub.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Suspension > Page 1720
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. For additional information, refer to Wheel Knuckle See: Steering and
Suspension/Suspension/Rear Knuckle/Service and
Repair.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 1729
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 1735
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 (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Front Drive Halfshaft nut.......................................................................................................................
........................................................................250 Nm (184 lb-ft)
Rear Drive Halfshaft nut.......................................................................................................................
........................................................................275 Nm (203 lb-ft)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
Wheel Fastener: Specifications
NOTICE: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout,
which will speed up the development of brake roughness, shudder and vibration.
Tighten the wheel nuts, using the pattern indicated,
to..............................................................................................................................135 Nm (100
lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front Suspension - Rear Wheel Drive (RWD)
Wheel Fastener: Service and Repair Front Suspension - Rear Wheel Drive (RWD)
Wheel Studs
Removal
1. Remove the wheel and tire.
2. NOTICE: 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 the new bolts to 165 Nm (122 lb-ft).
3. Remove the brake disc.
4. Using the C-Frame and Screw, remove the wheel stud.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 1745
Installation
1. NOTICE: 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.
NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud
serrations. Use enough washers (approximately 4) to allow the wheel stud to fully seat against the
hub flange.
Install approximately 4 washers and a new wheel nut on the wheel stud and tighten the nut until the
stud seats against the flange. -
Discard the wheel nut and washers.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 1746
Wheel Fastener: Service and Repair Rear Suspension
Wheel Studs
Removal
NOTICE: 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.
NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 1747
2. NOTICE: 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.
NOTICE: 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 C-Frame and Screw, press the wheel stud until it makes contact with the edge of the
wheel knuckle.
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. NOTICE: 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.
NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud
serrations. Use enough washers (approximately 4) to allow the wheel stud to fully seat against the
hub flange.
Place approximately 4 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. NOTICE: A plug must be installed in place of the knockout to prevent contamination to the
parking brake shoe assemblies.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 1748
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 (V6-4.0L (2009))
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.
WARNING: 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.
WARNING: 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.
WARNING: 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.
WARNING: 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.
NOTICE: 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.
NOTICE: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on
lift without first checking for possible interference.
NOTICE: 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.
NOTICE: 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
Lifting Points
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page
1752
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Description and Operation
Variable Valve Timing Actuator: Description and Operation
Variable Camshaft Timing (VCT) System
Overview
The VCT system enables rotation of the camshaft(s) relative to the crankshaft rotation as a function
of engine operating conditions. There are four 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 four 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.
The VCT system knocking and noise concerns are diagnosed in the Testing and Inspection
section. For additional information, refer to the Engine System - General Information. Verification of
incorrect VCT phasing on a warm engine operating below 1500 RPM can be isolated using a
stethoscope and by monitoring the VCTADV, VCTADVERR and VCTDC PIDs using a scan tool. If
the VCT phaser does not maintain correct valve timing, low oil pressure or oil flow restrictions are
primary possible causes. Verify correct oil pressure and flow, refer to the Engine System - General
Information.
Variable Camshaft Timing (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 indicates 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), engine coolant
temperature (ECT), engine oil temperature (EOT), CMP,
throttle position (TP), mass air flow (MAF), and CKP sensors 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Description and Operation > Page 1759
achieved. A difference between the desired and actual camshaft position represents a position
error in the PCM VCT control loop. The PCM disables the VCT and places the camshaft in a
default position if a concern is detected. A related DTC is also set when the concern is detected.
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 two 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.
VCT System
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Solenoid > Component Information > Locations > VCT Solenoid 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Solenoid > Component Information > Locations > VCT Solenoid 1 > Page 1764
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Solenoid > Component Information > Diagrams > VCT Solenoid 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Solenoid > Component Information > Diagrams > VCT Solenoid 1 > Page 1767
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Solenoid > Component Information > Diagrams > Page 1768
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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Compression Check: Specifications
Compression Test - Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart.
Compression Pressure Limit Chart
If one or more cylinders reads 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 within 75% of the highest reading.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 1772
Compression Check: Testing and Inspection
Engine
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 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
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the
pistons in the low-reading cylinders. Repeat the
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 1773
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 within 75% of the highest reading.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing
> Component Information > Specifications
Camshaft Bearing: Specifications
Position the camshaft bearing caps and the 8 bolts for each set of camshaft bearing caps. Tighten
the bolts in the sequence shown in 2 stages. Stage 1: Tighten to.......................................................
...................................................................................................................................6 Nm (53 lb-in).
Stage 2: Tighten to...............................................................................................................................
.......................................................16 Nm (142 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Tighten the camshaft bolt to.................................................................................................................
..........................................................85 Nm (63 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures
Camshaft: Procedures
Camshaft Journal To Bearing Clearance - OHC Engines
Camshaft Journal to Bearing Clearance - OHC Engines
NOTE: Refer to the Engine system level for the specification.
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
Camshaft End Play - OHC Engines
NOTE: Refer to the Engine system level for the specification.
1. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play.
2. Position the camshaft to the rear of the cylinder head.
3. Zero the Dial Indicator Gauge.
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.
Camshaft Surface Inspection
Camshaft Surface Inspection
1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable
outside the contact area.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 1785
Camshaft Bearing Journal Diameter
Camshaft Bearing Journal Diameter
NOTE: Refer to the Engine system level for the specification.
1. Measure each camshaft journal diameter in 2 directions.
Camshaft Lobe Lift
Camshaft Lobe Lift
NOTE: Refer to the Engine system level for the specification.
1. Use the Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift.
- Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial
Indicator Gauge reading to figure the camshaft lobe lift.
Camshaft Runout
Camshaft Runout
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 1786
NOTE: Refer to the Engine system level for the specification.
1. NOTE: Camshaft journals must be within specifications before checking runout.
Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft runout.
- Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial
Indicator Gauge reading.
Camshaft Timing
Camshaft Timing
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 1787
1. Remove the camshaft roller followers. For additional information, refer to Camshaft Roller
Follower See: Rocker Arm Assembly/Service and
Repair/Removal and Replacement/Camshaft Roller Follower.
2. If necessary, rotate the accessory drive belt tensioner counterclockwise and remove the
accessory drive belt.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 1788
3. If necessary, remove the 3 bolts and position the generator aside.
4. If necessary, remove the 4 bolts and position the A/C compressor and power steering pump
bracket aside.
5. NOTE: The LH and RH camshafts must be retimed when either camshaft is disturbed.
Turn the crankshaft clockwise to position the No. 1 cylinder at Top Dead Center (TDC).
6. Remove the nut and position the wiring harness aside.
7. NOTICE: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will
result in damage to the damper
crankshaft sensor speed wheel and incorrect timing of the engine.
NOTE: The Crankshaft TDC Timing Tool must be installed on the damper and should contact the
engine block. This positions the engine at TDC.
Install the Crankshaft TDC Timing Tool.
8. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 to the RH cylinder head
and tighten the 2 top clamp bolts to 10 Nm (89
lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 1789
9. NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong
direction can damage the bolt.
Using the Torque Wrench Extension with the Camshaft Sprocket Nut Socket 303-565, loosen the
RH camshaft sprocket bolt.
10. Loosen the top 2 Camshaft Sprocket Holding Tool clamp bolts.
11. NOTE: The camshaft timing slots are off-center.
Position the camshaft timing slots below the centerline of the camshaft and install the Camshaft
Holding Tool and the Adapter for 303-577 on the front of the RH cylinder head.
12. Remove the RH hydraulic timing chain tensioner.
- Discard the washer.
13. Install the Timing Chain Tensioner.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 1790
14. NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong
direction can damage the bolt.
Tighten the bolts.
1. Tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts to 10 Nm (89 lb-in).
2. Calculate the correct torque wrench setting for the following torque.
Using the Torque Wrench Extension with the Camshaft Sprocket Nut Socket 303-565, tighten the
camshaft bolt to 85 Nm (63 lb-ft).
15. Remove the Timing Chain Tensioner.
16. NOTE: Install a new washer on the tensioner.
Install the RH hydraulic timing chain tensioner.
- Tighten to 44 Nm (32 lb-ft).
17. Remove the Camshaft Holding Tool, the Adapter for 303-577, the Camshaft Sprocket Holding
Tool and the Adapter for 303-564 from the RH
cylinder head.
18. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the front of the LH
cylinder head and tighten the top 2 clamp bolts to
10 Nm (89 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 1791
19. Loosen the LH camshaft sprocket bolt.
20. Loosen the top 2 clamp bolts on the Camshaft Sprocket Holding Tool to allow the camshaft
sprocket to rotate freely.
21. NOTE: The camshaft timing slots are off-center.
Position the camshaft timing slots below the centerline of the camshaft and install the Camshaft
Holding Tool and the Adapter for 303-577 on the rear of the LH cylinder head.
22. Remove the LH hydraulic timing chain tensioner.
- Discard the washer.
23. Install the Timing Chain Tensioner.
24. Tighten the bolts.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 1792
1. Tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts to 10 Nm (89 lb-in).
2. Tighten the LH camshaft bolt to 85 Nm (63 lb-ft).
25. Remove the Timing Chain Tensioner.
26. NOTE: Install a new washer on the tensioner.
Install the LH hydraulic timing chain tensioner.
- Tighten to 44 Nm (32 lb-ft).
27. Remove the Camshaft Holding Tool, the Adapter for 303-577, the Camshaft Sprocket Holding
Tool and the Adapter for 303-564 from the LH
cylinder head.
28. Remove the Crankshaft TDC Timing Tool.
29. Position the battery cable bracket and install the nut.
- Tighten to 20 Nm (177 lb-in).
30. If necessary, position the A/C compressor and power steering pump bracket and install the 4
bolts.
- Tighten to 42 Nm (31 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 1793
31. If necessary, position the generator and install the 3 bolts.
- Tighten to 47 Nm (35 lb-ft).
32. If necessary, rotate the accessory drive belt tensioner counterclockwise and install the
accessory drive belt.
33. Install the camshaft roller followers. For additional information, refer to Camshaft Roller
Follower See: Rocker Arm Assembly/Service and
Repair/Removal and Replacement/Camshaft Roller Follower.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 1794
Camshaft: Removal and Replacement
Valve Train Components - Exploded View
Valve Train Components - Exploded View
Accessory Drive Belt and Wiring Harness Bracket
A/C Compressor and Power Steering Pump Bracket
Valve Train Components - RH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 1795
Valve Train Components - LH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 1796
1. For additional information, refer to the procedures.
Camshafts
Camshafts
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 1797
Removal
Both sides
1. Remove the camshaft roller followers. For additional information, refer to Camshaft Roller
Follower See: Rocker Arm Assembly/Service and
Repair/Removal and Replacement/Camshaft Roller Follower.
2. Remove the nut and position the wiring harness bracket aside.
3. NOTE: Carry out the RH and LH camshaft timing procedure when either camshaft is serviced.
Rotate the crankshaft clockwise to position the No. 1 cylinder at Top Dead Center (TDC).
4. NOTICE: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will
result in damage to the damper
crankshaft sensor speed wheel and incorrect timing of the engine.
NOTE: The Crankshaft TDC Timing Tool must be installed on the damper and should contact the
engine block. This positions the piston at TDC.
Install the Crankshaft TDC Timing Tool.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 1798
RH side
5. Remove the RH hydraulic timing chain tensioner.
- Discard the washer.
6. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the rear of the RH
cylinder head and tighten the top 2 clamp bolts to
10 Nm (89 lb-in).
7. NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong
direction can damage the bolt.
Using the Torque Wrench Extension and the Camshaft Sprocket Nut Socket, loosen the camshaft
sprocket bolt.
8. Remove the bolt and position the camshaft sprocket aside.
LH side
9. Remove the LH hydraulic timing chain tensioner.
- Discard the washer.
10. Rotate the accessory drive belt tensioner counterclockwise and detach the accessory drive belt
from the A/C compressor and power steering pump
pulleys.
11. Remove the bolts and position the A/C compressor and power steering pump bracket aside.
12. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the front of the LH
camshaft and tighten the 2 top clamp bolts to 10
Nm (89 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 1799
13. Remove the bolt and position the camshaft sprocket aside.
Both sides
14. NOTE: Mark the position of the camshaft bearing caps so they can be installed in their original
positions.
Remove the 8 bolts for each set of camshaft bearing caps in the sequence shown and remove the
camshaft bearing caps.
15. Remove the camshaft.
Installation
NOTE: Lubricate the camshaft journal bearing surfaces on the cylinder head, the camshaft journals
and the camshaft bearing caps with clean engine oil.
Both sides
1. Install the camshaft.
2. NOTE: The camshaft bearing caps must be installed in their original positions.
NOTE: After installing the bolts, check the camshaft for free rotation.
Position the camshaft bearing caps and the 8 bolts for each set of camshaft bearing caps.
- Tighten the bolts in the sequence shown in 2 stages. Stage 1: Tighten to 6 Nm (53 lb-in).
- Stage 2: Tighten to 16 Nm (142 lb-in).
RH side
3. NOTICE: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this
time. Tightening the bolt may result in
incorrect engine timing.
NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong
direction can damage the bolt.
Install the camshaft sprocket and loosely install the bolt.
LH side
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 1800
4. NOTICE: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this
time. Tightening the bolt may result in
incorrect engine timing.
Install the camshaft sprocket and loosely install the bolt.
Both sides
5. Time the camshafts. For additional information, refer to Camshaft Timing See:
Procedures/Camshaft Timing.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Procedures
Lifter / Lash Adjuster: Procedures
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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 1805
Lifter / Lash Adjuster: Removal and Replacement
Valve Train Components - Exploded View
Valve Train Components - Exploded View
Accessory Drive Belt and Wiring Harness Bracket
A/C Compressor and Power Steering Pump Bracket
Valve Train Components - RH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 1806
Valve Train Components - LH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 1807
1. For additional information, refer to the procedures.
Hydraulic Lash Adjuster
Hydraulic Lash Adjuster
Removal and Installation
1. Remove the camshaft roller followers. For additional information, refer to Camshaft Roller
Follower See: Rocker Arm Assembly/Service and
Repair/Removal and Replacement/Camshaft Roller Follower.
2. NOTE: Mark each hydraulic lash adjuster to make sure it is returned to its original position.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 1808
Remove the hydraulic lash adjusters.
3. NOTE: The hydraulic lash adjusters must be installed in their original positions.
NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair > Procedures
Rocker Arm Assembly: Procedures
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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair > Procedures > Page 1813
Rocker Arm Assembly: Removal and Replacement
Valve Train Components - Exploded View
Valve Train Components - Exploded View
Accessory Drive Belt and Wiring Harness Bracket
A/C Compressor and Power Steering Pump Bracket
Valve Train Components - RH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair > Procedures > Page 1814
Valve Train Components - LH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair > Procedures > Page 1815
1. For additional information, refer to the procedures.
Camshaft Roller Follower
Camshaft Roller Follower
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair > Procedures > Page 1816
Removal and Installation
1. Remove the LH and RH valve covers. For additional information, refer to Valve Cover - RH See:
Cylinder Head Assembly/Valve Cover/Service
and Repair/Valve Cover - RH and Valve Cover - LH See: Cylinder Head Assembly/Valve
Cover/Service and Repair/Valve Cover - LH.
2. Remove the fuel rail.
3. Remove the cooling fan.
4. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
5. NOTE: Mark each camshaft roller follower to make sure it is returned to its original position.
Using the Valve Spring Compressor, remove the camshaft roller followers.
6. NOTE: The camshaft roller followers must be installed in their original positions.
NOTE: Lubricate the camshaft roller followers with clean engine oil.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Description and Operation
Variable Valve Timing Actuator: Description and Operation
Variable Camshaft Timing (VCT) System
Overview
The VCT system enables rotation of the camshaft(s) relative to the crankshaft rotation as a function
of engine operating conditions. There are four 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 four 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.
The VCT system knocking and noise concerns are diagnosed in the Testing and Inspection
section. For additional information, refer to the Engine System - General Information. Verification of
incorrect VCT phasing on a warm engine operating below 1500 RPM can be isolated using a
stethoscope and by monitoring the VCTADV, VCTADVERR and VCTDC PIDs using a scan tool. If
the VCT phaser does not maintain correct valve timing, low oil pressure or oil flow restrictions are
primary possible causes. Verify correct oil pressure and flow, refer to the Engine System - General
Information.
Variable Camshaft Timing (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 indicates 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), engine coolant
temperature (ECT), engine oil temperature (EOT), CMP,
throttle position (TP), mass air flow (MAF), and CKP sensors 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Description and Operation > Page 1820
achieved. A difference between the desired and actual camshaft position represents a position
error in the PCM VCT control loop. The PCM disables the VCT and places the camshaft in a
default position if a concern is detected. A related DTC is also set when the concern is detected.
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 two 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.
VCT System
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Cover / Housing > Component Information > Service and Repair
Variable Valve Timing Cover / Housing: Service and Repair
Variable Camshaft Timing (VCT) Housing Cleaning and Inspection
1. Remove the screw and the Variable Camshaft Timing (VCT) oil control solenoid.
- To install, tighten to 5 Nm (44 lb-in).
2. Clean the mating surfaces and oil passages with metal surface prep. Follow the directions on the
packaging.
3. Inspect the VCT housing for pitting, cracks or damaged sealing surfaces. Install a new VCT
housing if damaged.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing >
Component Information > Specifications
Connecting Rod Bearing: Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing >
Component Information > Specifications > Page 1828
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing >
Component Information > Specifications > Page 1829
Connecting Rod Bearing: Service and Repair
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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications
Connecting Rod: Specifications
CONNECTING ROD
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Page 1833
ROD BEARING CAP
Tighten the 2 connecting rod nuts in 2 stages. Stage 1: Tighten to.....................................................
.................................................................................................................................20 Nm (177 lb-in).
Stage 2: Tighten an additional..............................................................................................................
...................................................................90 degrees.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Service and Repair > Connecting Rod Bearing Journal Taper and Out-of-Round
Connecting Rod: Service and Repair Connecting Rod Bearing Journal Taper and Out-of-Round
Connecting Rod Bearing Journal Taper and Out-of-Round
NOTE: Refer to the Engine system level for the specification.
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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Service and Repair > Connecting Rod Bearing Journal Taper and Out-of-Round > Page 1836
Connecting Rod: Service and Repair Connecting Rod Bearing Journal-to-Bearing Clearance
Connecting Rod Bearing Journal-to-Bearing Clearance
NOTE: Refer to the Engine system level for the specification.
NOTE: The crankshaft connecting rod journals must be within specifications to check the
connecting rod bearing journal clearance.
1. Remove the connecting rod bearing cap.
2. Position a piece of Plastigage across the bearing surface.
3. NOTE: Do not turn the crankshaft during this step.
Install and tighten to specifications, then remove the connecting rod bearing cap.
4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage
should be smooth and flat. A changing width indicates
a tapered or damaged connecting rod or connecting rod bearing.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Service and Repair > Connecting Rod Bearing Journal Taper and Out-of-Round > Page 1837
Connecting Rod: Service and Repair Connecting Rod Bend
Connecting Rod Bend
NOTE: Refer to the Engine system level for the specification.
1. Using the Feeler Gauge Set, measure the connecting rod bend on a suitable alignment fixture.
Follow the instructions of the fixture manufacturer.
Verify the bend measurement is within specification.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Service and Repair > Connecting Rod Bearing Journal Taper and Out-of-Round > Page 1838
Connecting Rod: Service and Repair Connecting Rod Bushing Diameter
Connecting Rod Bushing Diameter
NOTE: Refer to the Engine system level for the specification.
1. Use a telescoping gauge to determine the ID of the connecting rod bushing, if equipped.
2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Service and Repair > Connecting Rod Bearing Journal Taper and Out-of-Round > Page 1839
Connecting Rod: Service and Repair
Connecting Rod Bearing Journal Taper and Out-of-Round
Connecting Rod Bearing Journal Taper and Out-of-Round
NOTE: Refer to the Engine system level for the specification.
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.
Connecting Rod Bearing Journal-to-Bearing Clearance
Connecting Rod Bearing Journal-to-Bearing Clearance
NOTE: Refer to the Engine system level for the specification.
NOTE: The crankshaft connecting rod journals must be within specifications to check the
connecting rod bearing journal clearance.
1. Remove the connecting rod bearing cap.
2. Position a piece of Plastigage across the bearing surface.
3. NOTE: Do not turn the crankshaft during this step.
Install and tighten to specifications, then remove the connecting rod bearing cap.
4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage
should be smooth and flat. A changing width indicates
a tapered or damaged connecting rod or connecting rod bearing.
Connecting Rod Bend
Connecting Rod Bend
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Service and Repair > Connecting Rod Bearing Journal Taper and Out-of-Round > Page 1840
NOTE: Refer to the Engine system level for the specification.
1. Using the Feeler Gauge Set, 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 Bushing Diameter
Connecting Rod Bushing Diameter
NOTE: Refer to the Engine system level for the specification.
1. Use a telescoping gauge to determine the ID of the connecting rod bushing, if equipped.
2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification.
Connecting Rod Cleaning
Connecting Rod Cleaning
NOTICE: Do not use a caustic cleaning solution or damage to connecting rods can occur.
1. NOTE: The connecting rod large end is a matched set. The connecting rod cap must be installed
on the original connecting rod in the original
position. Do not reverse the cap. Parts are not interchangeable.
Mark and separate the parts and clean with solvent. Clean the oil passages.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Service and Repair > Connecting Rod Bearing Journal Taper and Out-of-Round > Page 1841
Connecting Rod Large End Bore
Connecting Rod Large End Bore
NOTE: Refer to the Engine system level for the specification.
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
Connecting Rod to Crankshaft Side Clearance
NOTE: Refer to the Engine system level for the specification.
1. Using the Feeler Gauge Set, measure the clearance between the connecting rod and the
crankshaft. Verify the measurement is within specification.
Connecting Rod Twist
Connecting Rod Twist
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Service and Repair > Connecting Rod Bearing Journal Taper and Out-of-Round > Page 1842
NOTE: Refer to the Engine system level for the specification.
1. Using the Feeler Gauge Set, measure the connecting rod twist on a suitable alignment fixture.
Follow the instructions of the fixture manufacturer.
Verify the measurement is within specification.
Connecting Rod-to-Piston Clearance
Connecting Rod-to-Piston Clearance
NOTE: Refer to the Engine system level for the specification.
1. Using the Feeler Gauge Set, measure the clearance between the connecting rod and the piston.
Verify the measurement is within specification.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications
Crankshaft Main Bearing: Specifications
MAIN BEARING CAP
Tighten the 8 bolts in the sequence shown in 2 stages. Stage 1: Tighten to.......................................
..................................................................................................................................................35 Nm
(26 lb-ft). Stage 2: Tighten an additional..............................................................................................
...................................................................................57 degrees.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications > Page 1846
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications > Page 1847
Crankshaft Main Bearing: Service and Repair
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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications
Crankshaft: Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round
Crankshaft: Service and Repair Crankshaft Main Bearing Journal Taper and Out-of-Round
Crankshaft Main Bearing Journal Taper and Out-of-Round
NOTE: Refer to the Engine system level for the specification.
1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions at each
end of the main bearing journal.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round > Page 1853
Crankshaft: Service and Repair Crankshaft Main Bearing Journal-To-Bearing Clearance
Crankshaft Main Bearing Journal-to-Bearing Clearance
NOTE: Refer to the Engine system level for the specification.
NOTE: Crankshaft main bearing journals must be within specifications before checking journal
clearance.
1. Remove the crankshaft main bearing caps and crankshaft main bearing.
2. Lay a piece of Plastigage across the face of each crankshaft main bearing surface.
3. NOTE: Do not turn the crankshaft while carrying out this procedure.
Install and remove the crankshaft main bearing cap.
4. Verify the crankshaft journal clearance.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round > Page 1854
Crankshaft: Service and Repair Crankshaft End Play
Crankshaft End Play
NOTE: Refer to the Engine system level for the specification.
1. Install the Dial Indicator Gauge with Holding Fixture.
2. Position the crankshaft to the rear of the cylinder block.
3. Zero the Dial Indicator Gauge.
4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round > Page 1855
Crankshaft: Service and Repair Crankshaft Main Bearing Journal Diameter
Crankshaft Main Bearing Journal Diameter
NOTE: Refer to the Engine system level for the specification.
1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling
and Bleeding See: Cooling System/Service and
Repair/Procedures/Cooling System Draining, Filling and Bleeding.
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. NOTICE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Using the Strap Wrench, tighten the bolt in 2 stages. Stage 1: Tighten to...........................................
..............................................................................................................................................55 Nm
(41 lb-ft). Stage 2: Rotate an additional................................................................................................
...................................................................................85 degrees.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1862
Harmonic Balancer - Crankshaft Pulley: Service and Repair
Crankshaft Pulley
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the fan shroud.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1863
3. Remove the accessory drive belt.
4. NOTE: This bolt is torque-to-yield and cannot be reused.
Using the Strap Wrench to hold the crankshaft pulley, remove the bolt.
5. NOTE: If the pulley bolt is not installed, the tool will bottom out before the pulley is off.
Install the crankshaft pulley bolt 2 to 3 turns. Using the 2 Crankshaft Vibration Damper Removers
and the two 8-mm bolts, remove the crankshaft pulley.
- Discard the crankshaft pulley bolt.
Installation
1. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
2. Using the Strap Wrench to hold the crankshaft pulley, install a new crankshaft pulley bolt.
Tighten the bolt in 2 stages.
- Stage 1: Tighten to 55 Nm (41 lb-ft).
- Stage 2: Tighten an additional 85 degrees.
3. Install the accessory drive belt.
4. Install the fan shroud.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications > Page 1867
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures
Piston: Procedures
Piston Inspection
Piston Inspection
NOTICE: 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
Piston Pin Bore Diameter
NOTE: Refer to the Engine system level for the specification.
1. 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.
Piston Diameter
Piston Diameter
NOTE: Refer to the Engine system level for the specification.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures > Page 1870
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
Piston To Cylinder Bore Clearance
NOTE: Refer to the Engine system level for the specification.
1. Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore
clearance.
Piston Selection
Piston Selection
NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting
a piston.
1. Select a piston size based on the cylinder bore.
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
Piston Ring End Gap
NOTICE: Use care when fitting piston rings to avoid possible damage to the piston ring or the
cylinder bore.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures > Page 1871
NOTE: Piston rings should not be transferred from one piston to another.
NOTE: Refer to the Engine system level for the specification.
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 the Feeler Gauge Set to measure the top piston ring end gap and the second piston ring
end gap.
Piston Ring-To-Groove Clearance
Piston Ring-to-Groove Clearance
NOTE: Refer to the Engine system level for the specification.
1. Inspect the piston for ring land damage or accelerated wear.
2. Using the Feeler Gauge Set, measure the piston ring-to-groove clearance.
Piston Pin Diameter
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures > Page 1872
Piston Pin Diameter
NOTE: Refer to the Engine system level for the specification.
1. Measure the piston pin diameter in 2 directions at the points shown. Verify the diameter is within
specification.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures > Page 1873
Piston: Overhaul
Piston
Disassembly
NOTE: The connecting rod bolts and nuts cannot be reused.
NOTE: Mark the position of the parts, so they can be installed in their original positions.
1. Remove the connecting rod bearings from the connecting rod and cap.
2. Remove the piston rings from the piston.
3. Using the Piston Pin Service Set, press the piston pin out of the connecting rod and piston
assembly.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures > Page 1874
Assembly
NOTE: Lubricate all parts with clean engine oil.
NOTE: Install the piston in the connecting rod with the cylinder number side of the rod and the
indentation notch in the piston on the same side.
NOTE: The oil hole in the connecting rod must face the RH side of the cylinder block and the arrow
on the piston must face the front of the engine block.
1. NOTE: If the piston pin is removed from the piston, a new piston and piston pin must be used.
Do not reuse the piston or the piston pin.
Gradually heat the pin bore side of the connecting rod to approximately 232°C-316°C
(467°F-626°F) and immediately install the piston pin.
2. Using the Piston Pin Service Set, press the piston pin into the piston and connecting rod
assembly.
3. Install the piston rings.
4. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced
around the circumference of the piston.
5. Install the connecting rod bearings in the connecting rod and cap.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications > Page 1878
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
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. 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.
NOTE: It may be necessary to reposition the lower end of the door jam weatherstripping to remove
the front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the Inertia Fuel Shutoff (IFS) switch electrical connector.
4. Start the engine and allow it to idle until it stalls.
5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail
pressure has been released.
6. Turn the ignition switch to the OFF position.
7. When the fuel system service is complete, reconnect the IFS switch electrical connector.
8. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before
starting the engine.
9. Start the vehicle and check the fuel system for leaks.
10. Install the front passenger side interior kick panel.
11. Install the front passenger door frame scuff plate.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Service and Repair > Procedures
Rocker Arm Assembly: Procedures
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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Service and Repair > Procedures > Page 1887
Rocker Arm Assembly: Removal and Replacement
Valve Train Components - Exploded View
Valve Train Components - Exploded View
Accessory Drive Belt and Wiring Harness Bracket
A/C Compressor and Power Steering Pump Bracket
Valve Train Components - RH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Service and Repair > Procedures > Page 1888
Valve Train Components - LH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Service and Repair > Procedures > Page 1889
1. For additional information, refer to the procedures.
Camshaft Roller Follower
Camshaft Roller Follower
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Service and Repair > Procedures > Page 1890
Removal and Installation
1. Remove the LH and RH valve covers. For additional information, refer to Valve Cover - RH See:
Valve Cover/Service and Repair/Valve Cover RH and Valve Cover - LH See: Valve Cover/Service and Repair/Valve Cover - LH.
2. Remove the fuel rail.
3. Remove the cooling fan.
4. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
5. NOTE: Mark each camshaft roller follower to make sure it is returned to its original position.
Using the Valve Spring Compressor, remove the camshaft roller followers.
6. NOTE: The camshaft roller followers must be installed in their original positions.
NOTE: Lubricate the camshaft roller followers with clean engine oil.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ignition and PCV Components, and Camshaft Position (CMP) Sensor
LH Valve Cover
Removal and Installation
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 1895
1. Remove the intake manifold. For additional information, refer to Intake Manifold See: Intake
Manifold/Service and Repair.
2. Disconnect the Camshaft Position (CMP) sensor electrical connector.
3. Disconnect the ignition coil electrical connector. Detach the wiring harness retainer.
4. Disconnect the 3 fuel injector electrical connectors. Detach the wiring harness retainers.
5. Remove the PCV valve tube.
6. Disconnect the PCV valve electrical connector.
7. Detach the spark plug wire retainers.
8. Remove the 6 bolts and the valve cover.
- To install, tighten to 10 Nm (89 lb-in).
9. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean sealing surfaces. These tools
cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of the old valve cover gasket.
Clean and inspect the sealing surfaces and the gasket. Install a new gasket if necessary.
10. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 1896
Valve Cover: Service and Repair Valve Cover - RH
Valve Cover - RH
Heater Hose Tube, Spark Plug Wires, Fuel Supply Tube and Crankcase Ventilation Tube
RH Valve Cover
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 1897
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.
WARNING: 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.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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. Disconnect the spring lock coupling from the fuel supply tube.
2. Disconnect the battery ground cable.
3. Remove the intake manifold. For additional information, refer to Intake Manifold See: Intake
Manifold/Service and Repair.
4. Remove the heater hose tube bracket rear bolt.
- To install, tighten to 23 Nm (17 lb-ft).
5. Remove the heater hose tube bracket front bolt.
- To install, tighten to 34 Nm (25 lb-ft).
6. Loosen the exhaust manifold-to-EGR system module tube lower fitting and remove the tube.
- To install, tighten to 34 Nm (25 lb-ft).
7. NOTICE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary
O-ring seals may cause the fuel system to leak.
Remove the fuel supply tube-to-valve cover bracket bolt, the 4 fuel supply tube bolts and the fuel
supply tube. Remove and discard the O-ring seals.
- Install new O-ring seals and lubricate them with clean engine oil.
- To install, tighten to 6 Nm (53 lb-in).
8. Detach the spark plug wire retainers and position the spark plug wires aside.
9. Remove the crankcase ventilation tube.
10. Remove the 6 bolts and the valve cover.
- To install, tighten to 10 Nm (89 lb-in).
11. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean sealing surfaces. These tools
cause scratches which make leak paths. Use a plastic scraping tool to remove all traces of the old
valve cover gasket.
Clean and inspect the sealing surfaces and the gasket. Install a new gasket if necessary.
12. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
NOTE: Refer to the Engine system level for the specification.
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 inside 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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Service and Repair > Valve and Seat Refacing Measurements
Valve Seat: Service and Repair Valve and Seat Refacing Measurements
Valve Seat Inspection
Valve and Seat Refacing Measurements
NOTE: Refer to the Engine system level for the specification.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Service and Repair > Valve and Seat Refacing Measurements > Page 1905
Valve Seat: Service and Repair Valve Seat Width
Valve Seat Width
NOTE: Refer to the Engine system level for the specification.
1. Measure the valve seat width. If necessary, grind the valve seat to specification.
- Measure the intake valve seat width.
- Measure the exhaust valve seat width.
- Recheck the valve spring installed length after the seats have been ground, and shim the valve
springs as necessary to achieve the correct installed spring length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Service and Repair > Valve and Seat Refacing Measurements > Page 1906
Valve Seat: Service and Repair Valve Seat Runout
Valve Seat Runout
NOTE: Refer to the Engine system level for the specification.
1. Use a valve seat runout gauge to check valve seat runout.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Valve Spring Installed Length
NOTE: Refer to the Engine system level for the specification.
1. Measure the installed length of each valve spring.
Valve Spring Free Length
Valve Spring Free Length
NOTE: Refer to the Engine system level for the specification.
1. Measure the free length of each valve spring.
Valve Spring Squareness
Valve Spring Squareness
1. Measure the out-of-square on each valve spring.
- Turn the valve spring and observe the space between the top of the valve spring and the square.
Valve Spring Strength
Valve Spring Strength
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Procedures > Page 1911
NOTE: Refer to the Engine system level for the specification.
1. Use the Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the
specified valve spring length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Procedures > Page 1912
Valve Spring: Removal and Replacement
Valve Train Components - Exploded View
Valve Train Components - Exploded View
Accessory Drive Belt and Wiring Harness Bracket
A/C Compressor and Power Steering Pump Bracket
Valve Train Components - RH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Procedures > Page 1913
Valve Train Components - LH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Procedures > Page 1914
1. For additional information, refer to the procedures.
Valve Springs
Valve Springs
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Procedures > Page 1915
Removal and Installation
1. Remove the camshaft roller followers. For additional information, refer to Camshaft Roller
Follower See: Rocker Arm Assembly/Service and
Repair/Removal and Replacement/Camshaft Roller Follower.
2. Position the piston of the cylinder being serviced at Top Dead Center (TDC).
3. NOTICE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air
pressure will allow the valve to fall into the
cylinder. If air pressure must be removed, support the valve prior to removal.
Hold the valves in the cylinder head.
- Remove the spark plug of the cylinder being serviced.
- Use a suitable tool to apply air pressure to the cylinder.
4. Using the Valve Spring Compressor, remove the valve spring retainer keys, the valve spring
retainers and the valve springs.
5. NOTE: Lubricate the valve springs, the retainers and the retainer keys with clean engine oil.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
NOTE: Refer to the Engine system level for the specification.
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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Valve Stem Diameter > Page 1920
Valve: Service and Repair Valve Inspection
Valve Inspection
1. Inspect the following valve areas:
1. The end of the stem for grooves or scoring.
2. The valve face and the edge for pits, grooves or scores.
3. The valve head for signs of burning, erosion, warpage and cracking.
4. The valve margin for wear.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Valve Stem Diameter > Page 1921
Valve: Service and Repair Valve Stem To Valve Guide Clearance
Valve Stem to Valve Guide Clearance
NOTE: Refer to the Engine system level for the specification.
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 Valve Guide Clearance Gauge toward the Dial Indicator Gauge with Holding Fixture
and zero the Dial Indicator Gauge. Move the
Valve Guide Clearance Gauge away from the Dial Indicator Gauge with Holding Fixture and note
the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Diagrams
Drive Belt: Diagrams
Accessory Drive Belt Routing
Front End Accessory Drive (FEAD) - 4.0L SOHC
Front End Accessory Drive (FEAD) - 4.6L (3V)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Drive Belt - Noise/Flutter
Drive Belt: Testing and Inspection Drive Belt - Noise/Flutter
Accessory Drive
Drive Belt - Noise/Flutter
NOTICE: 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.
- the A/C anti-slugging strategy executes after a long hot heat soak.
- 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Drive Belt - Noise/Flutter > Page 1928
Drive Belt: Testing and Inspection Drive Belt - Incorrect Installation
Accessory Drive
Drive Belt - Incorrect Installation
NOTICE: 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
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View
Drive Belt: Service and Repair Front End Accessory Drive (FEAD) - Exploded View
Front End Accessory Drive (FEAD) - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View > Page 1931
Drive Belt: Service and Repair Accessory Drive Belt
Accessory Drive Belt - 4.0L SOHC
Removal and Installation
1. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt.
2. To install, reverse the removal procedure.
- For correct belt routing, refer to Accessory Drive See: Description and Operation, Accessory Drive
Belt Routing, Front End Accessory Drive (FEAD) - 4.0L SOHC in the Description and Operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Testing and Inspection > Belt Tensioner - Mechanical
Drive Belt Tensioner: Testing and Inspection Belt Tensioner - Mechanical
Accessory Drive
Component Tests
Belt Tensioner - Mechanical
The only mechanical check that needs to be made is a check for tensioner stick, grab or bind.
1. With the engine off, check routing of the accessory drive belt. Refer to the illustrations under
Accessory Drive See: Description and Operation in
the Description and Operation.
2. NOTE: The accessory drive belt tensioner spring is very strong and requires substantial force to
release.
Using a suitable, commercially available serpentine belt tensioner release tool, release the tension
on the belt and detach the accessory drive belt 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.
4. If the tensioner is saturated with oil and grease internally, install a new tensioner.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Testing and Inspection > Belt Tensioner - Mechanical > Page 1936
Drive Belt Tensioner: Testing and Inspection Belt Tensioner - Dynamics
Accessory Drive
Component Tests
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
accessory drive belt tensioner movement. Check rideout condition by installing a new belt. If
excessive accessory drive belt tensioner movement still exists, install a new accessory drive belt
tensioner.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View
Drive Belt Tensioner: Service and Repair Front End Accessory Drive (FEAD) - Exploded View
Front End Accessory Drive (FEAD) - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View >
Page 1939
Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner
Accessory Drive Belt Tensioner - 4.0L SOHC
Removal and Installation
1. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt.
2. Remove the bolt and the accessory drive belt tensioner.
- To install, tighten the bolt to 47 Nm (35 lb-ft).
3. To install, reverse the removal procedure.
- For correct belt routing, refer to Accessory Drive See: Description and Operation, Accessory Drive
Belt Routing, Front End Accessory Drive (FEAD) - 4.0L SOHC in the Description and Operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 system and procedure for special instructions on loosening and
tightening mount fasteners.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. NOTICE: Do not twist or strain the powertrain/drivetrain mounts or damage to the mounts may
occur.
Start the vehicle and move it in forward 0.6-1.2 m (2-4 ft). Then move the vehicle in reverse the
same distance.
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 1944
Engine Mount: Removal and Replacement
Cylinder Block Cradle
Cylinder Block Cradle
Front End Components
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 1945
Upper Cooling Fan Shroud
Engine Support Insulator Bolt and Nut and Heater Tube Bracket Bolt
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 1946
Stabilizer Bar and Crossmember
Front Axle - Four-Wheel Drive (4WD) Vehicles
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 1947
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.
3. Remove the Air Cleaner (ACL) outlet tube.
4. Remove the starter.
5. Remove the oil pump screen and pickup tube. For additional information, refer to Oil Pump
Screen and Pickup Tube See: Engine Lubrication/Oil
Pick Up/Strainer/Service and Repair/Oil Pump Screen and Pickup Tube.
6. Remove the weatherstrip.
7. Remove the bolt and position the power steering fluid reservoir aside.
8. NOTICE: Allow the engine to cool before removing the coolant expansion tank. The radiator
draws coolant from the coolant expansion
tank as the engine cools. If the coolant expansion tank is removed before the engine cools, the
radiator will draw air into the system, resulting in possible engine damage.
Disconnect the coolant overflow hose. Remove the 2 bolts and the coolant expansion tank.
9. Remove the 2 bolts, unclip the clips and remove the upper fan shroud.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 1948
10. Remove the heater tube bracket front bolt.
11. Install the Engine Lifting Bracket using the heater tube bracket front bolt.
- Tighten to 23 Nm (17 lb-ft).
12. NOTE: This is not a typical setup. Only the right side of the engine will be raised.
Install the Engine Support Bar and the 2 Adapters for 303-290A.
All-Wheel Drive (AWD) vehicles
13. Remove the 4 bolts and the 2 stabilizer bar brackets.
14. Remove the 4 bolts and the crossmember.
All vehicles
15. Remove the RH engine support insulator nut.
16. Remove the LH engine support insulator through bolt.
17. Remove the 2 transmission-to-cylinder block cradle bolts.
18. NOTE: Cylinder block cradle is shown removed for clarity. Note the location of the 2 Torx head
bolts at the rear of the cylinder block cradle.
Remove the 2 cylinder block cradle rear bolts.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 1949
19. Remove the 20 bolts and 2 nuts along the outside of the cylinder block cradle.
20. NOTE: Note the location of the 2 silver-colored bolts that have washer seals. They must be
installed in the same position with new washer seals.
Remove the 8 cylinder block cradle inner bolts and the 2 washer seals.
- Discard the washer seals.
21. Raise the engine.
AWD vehicles
22. WARNING: Secure the 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 front axle with a suitable jack.
23. Disconnect the vent hose from the axle housing vent tube.
24. NOTICE: Any time bolts, washers, spacers or nuts are loosened in the axle housing for any
reason, install new components to prevent
damage.
Remove and discard the 3 axle housing bolts and 3 flagnuts. Lower the axle.
All vehicles
25. Remove the cylinder block cradle.
Installation
All vehicles
1. NOTICE: Failure to back off the set screws may result in damage to the cylinder block cradle.
Back the set screws off until they are below the cylinder block cradle boss.
2. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools
cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of the old cylinder block cradle gasket and sealant.
NOTE: Gasket material as well as silicone sealant may be present in the cavities in the main
bearing cap. This material must be removed completely prior to assembly.
Clean the gasket mating surfaces, making sure all the sealant is removed from the cavities on the
rear main bearing cap. To clean the sealing area, use a plastic scraping tool, silicone gasket
remover and metal surface prep. Follow the directions on the packaging.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 1950
3. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned. To clean the sealing area, use silicone gasket
remover and metal surface prep. Follow the directions on the packaging. Failure to follow this
procedure may cause future oil leakage.
Apply silicone in the 6 places shown.
4. Position a new gasket and the cylinder block cradle. Install the outer 20 bolts and 2 nuts
finger-tight.
5. Install the 2 cylinder block cradle rear Torx bolts finger-tight.
6. Install the 2 transmission-to-cylinder block cradle bolts.
- Tighten to 47 Nm (35 lb-ft).
7. Tighten the outer 20 bolts and 2 nuts.
- Tighten the nuts to 10 Nm (89 lb-in).
- Tighten the bolts to 14 Nm (124 lb-in).
8. Tighten the 2 cylinder block cradle rear Torx bolts.
- Tighten to 10 Nm (89 lb-in).
9. Tighten the 8 inserts.
- Tighten to 3 Nm (27 lb-in).
10. Install the 2 silver-colored bolts and new washer seals finger-tight.
11. Install the 6 remaining inner bolts finger-tight.
12. Tighten the 8 inner bolts in the sequence shown in 2 stages.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 1951
- Stage 1: Tighten to 15 Nm (133 lb-in).
- Stage 2: Tighten to 34 Nm (25 lb-ft).
AWD vehicles
13. NOTICE: Any time bolts, washers, spacers or nuts are loosened in the axle housing for any
reason, install new components to prevent
damage.
Raise the axle housing into position and install 3 new bolts and nuts.
- Tighten to 66 Nm (49 lb-ft).
14. Connect the vent hose to the differential housing vent tube.
All vehicles
15. Lower the engine and remove the Engine Support Bar and the Adapters for 303-290A.
16. Install the LH engine support insulator through bolt and nut.
- Tighten to 103 Nm (76 lb-ft).
17. Install the RH engine support insulator nut.
- Tighten to 90 Nm (66 lb-ft).
AWD vehicles
18. Position the crossmember and install the 4 bolts.
- Tighten to 103 Nm (76 lb-ft).
19. Position the 2 stabilizer bar brackets and install the 4 bolts.
- Tighten to 55 Nm (41 lb-ft).
All vehicles
20. Install the oil pump screen and pickup tube. For additional information, refer to Oil Pump
Screen and Pickup Tube See: Engine Lubrication/Oil
Pick Up/Strainer/Service and Repair/Oil Pump Screen and Pickup Tube.
21. Install the starter.
22. Remove the Engine Lifting Bracket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 1952
23. Install the heater tube bracket front bolt.
- Tighten to 34 Nm (25 lb-ft).
24. Position the upper fan shroud and install the 2 bolts.
- Tighten to 7 Nm (62 lb-in).
25. Position the coolant expansion tank, install the 2 bolts and connect the coolant overflow hose.
- Tighten to 7 Nm (62 lb-in).
26. Position the power steering fluid reservoir and install the bolt.
- Tighten to 7 Nm (62 lb-in).
27. Install the weatherstrip.
28. Install the ACL outlet pipe.
29. Connect the battery ground cable.
Engine Support Insulators
Engine Support Insulators
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 1953
Front End Components
Upper Cooling Fan Shroud
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 1954
Front Axle - Four-Wheel Drive (4WD) Vehicles
RH Inner Fender Splash Shield
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 1955
Engine Support Insulator - LH
Engine Support Insulator - RH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 1956
Removal and Installation
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.
3. Remove the weatherstrip.
4. Remove the bolt and position the power steering fluid reservoir aside.
- To install, tighten to 7 Nm (62 lb-in).
5. NOTICE: Allow the engine to cool before removing the coolant expansion tank. The radiator
draws coolant from the coolant expansion
tank as the engine cools. If the coolant expansion tank is removed before the engine cools, the
radiator will draw air into the system, resulting in possible engine damage.
Disconnect the coolant overflow hose. Remove the 2 bolts and the coolant expansion tank.
- To install, tighten to 7 Nm (62 lb-in).
6. Remove the 2 bolts, unclip the clips and remove the upper fan shroud.
- To install, tighten to 7 Nm (62 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 1957
7. Remove the bolt and install the Engine Lifting Bracket.
- Tighten to 42 Nm (31 lb-ft).
8. Install the Engine Support Bar and the 2 Adapters for 303-290A.
9. Remove the LH engine support insulator through bolt.
- To install, tighten to 103 Nm (76 lb-ft).
10. Remove the 5 pushpins and the RH inner fender splash shield.
11. Remove the 3 RH engine support insulator nuts.
- To install, tighten to 90 Nm (66 lb-ft).
12. Raise the engine approximately 60 mm (2.36 in).
13. Remove the RH engine support insulator.
All-Wheel Drive (AWD) vehicles
14. Remove the 4 bolts and the 2 stabilizer bar brackets. 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 axle housing with a suitable jack.
16. Disconnect the axle housing vent hose from the axle housing vent tube.
17. NOTICE: Any time bolts, washers, spacers or nuts are loosened in the axle housing for any
reason, install new components to prevent
damage.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 1958
Remove and discard the 3 axle housing bolts and 3 flagnuts. Lower the axle housing approximately
25 mm (1 in).
- To install, tighten to 66 Nm (49 lb-ft).
All vehicles
18. Remove the nut and the LH engine support insulator.
- To install, tighten to 90 Nm (66 lb-ft).
19. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View
Idler Pulley: Service and Repair Front End Accessory Drive (FEAD) - Exploded View
Front End Accessory Drive (FEAD) - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View > Page 1963
Idler Pulley: Service and Repair Accessory Drive Belt Idler Pulley
Accessory Drive Belt Idler Pulley - 4.0L SOHC
Removal and Installation
1. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt.
2. Remove the bolt and the accessory drive belt idler pulley.
- To install, tighten to 47 Nm (35 lb-ft).
3. To install, reverse the removal procedure.
- For correct belt routing, refer to Accessory Drive See: Description and Operation, Accessory Drive
Belt Routing, Front End Accessory Drive (FEAD) - 4.0L SOHC in the Description and Operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications
Engine Oil Pressure: Specifications
Oil pressure minimum at 2,000 rpm (engine at normal operating
temperature)..............................................................................................103 kPa (15 psi)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications > Page 1968
Engine Oil Pressure: Testing and Inspection
Engine
Oil Pressure Test
NOTICE: Inspect the engine for installation of an aftermarket oil filter. Review oil and filter
maintenance history to make sure that the vehicle has not gone beyond the standard Ford
recommended oil change intervals. Check the engine oil level and check the oil for contamination.
If the oil is contaminated, engine damage can occur. The source of the contamination must be
identified and repaired as necessary.
1. Disconnect and remove the Engine Oil Pressure (EOP) switch from the engine.
2. Connect the Oil Pressure Gauge to the oil pressure port.
3. Run the engine until normal operating temperature is reached.
4. With the engine at idle record the gauge reading.
5. Run the engine at 2,000 rpm and record the gauge reading.
6. The oil pressure should be within specifications; refer to the specifications in the appropriate
engine system.
7. If the pressure is not within specification, Go To Pinpoint Test B. See: Testing and
Inspection/Pinpoint Tests/Pinpoint Test B: Low Oil Pressure
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Lubrication Components - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil
With Filter ............................................................................................................................................
............................................................. 4.7L (5.0 Qt)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications > Page 1976
Engine Oil: Fluid Type Specifications
Engine Oil
U.S. .........................................................................................................................................
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil Canada
....................................................................................................................................................
Motorcraft SAE 5W-30 Super Premium Motor Oil
Note: Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only have the
API Certification mark and meet the requirements of Ford Specification WSS-M2C929-A.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component
Information > Service and Repair
Oil Cooler: Service and Repair
Oil Cooler
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Drain the cooling system.
3. Remove and discard the oil filter.
- To install, tighten to 13 Nm (115 lb-in).
4. Disconnect the oil cooler inlet hose from the oil cooler.
5. Disconnect the heater hose from the oil cooler.
6. Loosen the threaded insert and remove the oil cooler.
- To install, tighten to 57 Nm (42 lb-ft).
7. To install, reverse the removal procedure.
- Install a new oil filter.
- Check the engine oil and fill as necessary.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the RH exhaust manifold. For additional information, refer to Exhaust Manifold - RH
See: Exhaust System/Exhaust Manifold/Service
and Repair/Removal and Replacement/Exhaust Manifold - RH.
3. Remove and discard the oil filter.
- To install, tighten to 13 Nm (115 lb-in).
Vehicles equipped with an oil cooler
4. NOTE: The oil cooler threaded insert is part of the oil cooler and is not removed.
Loosen the oil cooler threaded insert and position the oil cooler aside.
- To install, tighten to 57 Nm (42 lb-ft).
All vehicles
5. Remove the bolt and the oil filter adapter.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Service and Repair > Page 1983
- To install, tighten to 57 Nm (42 lb-ft).
6. To install, reverse the removal procedure.
- Install a new oil filter.
- Check the engine oil and fill as necessary.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications
Oil Pan: Specifications
Install the gasket, the oil pan and the 10 bolts. Tighten to...................................................................
...................................................................................................................................11 Nm (97 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Service and Repair > Engine Lubrication Components - Exploded View
Oil Pan: Service and Repair Engine Lubrication Components - Exploded View
Engine Lubrication Components - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1989
Oil Pan: Service and Repair Oil Pan
Oil Pan
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the drain plug and drain the engine oil.
- To install, tighten to 26 Nm (19 lb-ft).
3. Remove the 10 bolts, the oil pan and the gasket. Discard the gasket.
- To install, tighten to 11 Nm (97 lb-in).
4. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean sealing surfaces. These tools
cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of the old oil pan gasket.
Clean and inspect the sealing surfaces.
5. To install, reverse the removal procedure.
6. Fill the engine with clean engine oil.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations
Oil Pressure Sender: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations > Page 1993
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations > Page 1994
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair > Engine Lubrication Components - Exploded View
Oil Pick Up/Strainer: Service and Repair Engine Lubrication Components - Exploded View
Engine Lubrication Components - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1999
Oil Pick Up/Strainer: Service and Repair Oil Pump Screen and Pickup Tube
Oil Pump Screen and Pickup Tube
Removal and Installation
1. Remove the oil pan. For additional information, refer to Oil Pan See: Oil Pan/Service and
Repair/Oil Pan.
2. Remove the bolt and the oil pump screen and pickup tube.
- To install, tighten to 10 Nm (89 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
Oil pressure minimum at 2,000 rpm (engine at normal operating
temperature)..............................................................................................103 kPa (15 psi)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications > Page 2004
Engine Oil Pressure: Testing and Inspection
Engine
Oil Pressure Test
NOTICE: Inspect the engine for installation of an aftermarket oil filter. Review oil and filter
maintenance history to make sure that the vehicle has not gone beyond the standard Ford
recommended oil change intervals. Check the engine oil level and check the oil for contamination.
If the oil is contaminated, engine damage can occur. The source of the contamination must be
identified and repaired as necessary.
1. Disconnect and remove the Engine Oil Pressure (EOP) switch from the engine.
2. Connect the Oil Pressure Gauge to the oil pressure port.
3. Run the engine until normal operating temperature is reached.
4. With the engine at idle record the gauge reading.
5. Run the engine at 2,000 rpm and record the gauge reading.
6. The oil pressure should be within specifications; refer to the specifications in the appropriate
engine system.
7. If the pressure is not within specification, Go To Pinpoint Test B. See: Testing and
Inspection/Pinpoint Tests/Pinpoint Test B: Low Oil Pressure
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 Control Components
Engine Oil Temperature (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.
Typical Thread Type Sensor
Typical EOT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Intake Manifold
Intake Manifold: Specifications Intake Manifold
Tighten to..............................................................................................................................................
........................................................11 Nm (97 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Intake Manifold > Page 2012
Intake Manifold: Specifications Throttle Body
Remove the 4 bolts, the TB and the gasket. Discard the gasket. To install, tighten to........................
..............................................................................................................................................................
..9 Nm (80 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 2013
Intake Manifold: Service and Repair
Intake Manifold
Intake Manifold Connections
Intake Manifold
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 2014
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.
WARNING: 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.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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 Air Cleaner (ACL) outlet pipe.
2. Disconnect the battery ground cable.
3. Detach the Knock Sensor (KS) electrical connector from the intake manifold.
4. Disconnect the PCV tube from the intake manifold.
5. Disconnect the brake booster vacuum hose from the intake manifold.
6. Disconnect the main vacuum harness fitting from the intake manifold.
7. Disconnect the Evaporative Emission (EVAP) tube from the intake manifold.
8. Disconnect the EGR system module electrical connector.
9. Detach the wiring harness retainer.
10. Disconnect the EGR system module vacuum fitting.
11. Loosen the fitting and disconnect the exhaust manifold-to-EGR system module tube from the
EGR system module.
- To install, tighten to 34 Nm (25 lb-ft).
12. Disconnect the Throttle Position (TP) sensor electrical connector.
13. Disconnect the Electronic Throttle Body (ETB) electrical connector.
14. Remove the nut and detach the wiring harness bracket from the ETB.
- To install, tighten to 9 Nm (80 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 2015
15. Remove the 8 bolts, the intake manifold and the 6 gaskets.
- To install, tighten to 11 Nm (97 lb-in).
16. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools
can cause scratches and gouges which can make leak paths. Use a plastic scraping tool to remove
all traces of the old intake manifold gaskets.
Clean the sealing surfaces and inspect the gaskets. Install new gaskets if necessary.
17. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically
including valve or piston damage, check the
intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to
follow these instructions can result in engine damage.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair
Crankshaft Main Bearing Seal: Service and Repair
Crankshaft Rear Seal
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Page 2020
Removal
1. Remove the flexplate. For additional information, refer to Flexplate See: Transmission and
Drivetrain/Flex Plate/Service and Repair/Removal and
Replacement.
2. Remove the spacer plate.
3. Remove the flexplate-to-crankshaft spacer.
4. NOTE: The original crankshaft rear seal does not have a metal speedy sleeve. Replacement
rear crankshaft seals come with a speedy sleeve. If
present, this sleeve must be removed before attempting to remove the seal.
If necessary, remove the speedy sleeve using 2 screwdrivers or small pry bars.
5. NOTICE: Avoid scratching or damaging the crankshaft rear seal running surface during removal
of the crankshaft rear seal. Scratches
or other damage to the crankshaft may cause oil leaks.
Using the Oil Seal Remover, remove the crankshaft rear seal.
Installation
1. NOTE: The new replacement crankshaft rear seal comes with a speedy sleeve. The speedy
sleeve must be installed with the crankshaft rear seal.
NOTE: Be sure the crankshaft rear sealing surface is clean and free of any rust or corrosion. To
clean the crankshaft rear seal surface area, use extra-fine emery cloth or extra-fine 0000 steel wool
with metal surface prep.
Lubricate the crankshaft rear oil seal with clean engine oil.
2. Install the Adapter for 303-579 and the Crankshaft Rear Oil Seal Screws.
3. Position the crankshaft rear seal with speedy sleeve on the Adapter for 303-579 and the
Crankshaft Rear Oil Seal Screws.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Page 2021
4. Using the Crankshaft Rear Oil Seal Installer, install the crankshaft rear seal with speedy sleeve.
5. Install the flexplate-to-crankshaft spacer.
6. Install the spacer plate.
7. Install the flexplate. For additional information, refer to Flexplate See: Transmission and
Drivetrain/Flex Plate/Service and Repair/Removal and
Replacement.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal
1. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley See:
Cylinder Block Assembly/Harmonic Balancer Crankshaft Pulley/Service and Repair.
2. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft front seal.
Installation
1. NOTE: Lubricate the new front seal with clean engine oil.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Component Information > Service and Repair > Page 2025
Using the Front Cover Aligner and the Crankshaft Vibration Damper Installer, install a new
crankshaft front seal.
2. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley See: Cylinder
Block Assembly/Harmonic Balancer Crankshaft Pulley/Service and Repair.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Valve Train Components - Exploded View
Valve Guide Seal: Service and Repair Valve Train Components - Exploded View
Valve Train Components - Exploded View
Accessory Drive Belt and Wiring Harness Bracket
A/C Compressor and Power Steering Pump Bracket
Valve Train Components - RH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Valve Train Components - Exploded View > Page 2030
Valve Train Components - LH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Valve Train Components - Exploded View > Page 2031
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Valve Train Components - Exploded View > Page 2032
Valve Guide Seal: Service and Repair Valve Seals
Valve Seals
Removal
1. Remove the valve springs. For additional information, refer to Valve Springs See: Cylinder Head
Assembly/Valve Spring/Service and
Repair/Removal and Replacement/Valve Springs.
2. Remove the valve seals.
Installation
1. NOTE: Lubricate the valve seals with clean engine oil.
Using the Valve Stem Seal Installer, install the valve seal.
2. Install the valve springs. For additional information, refer to Valve Springs See: Cylinder Head
Assembly/Valve Spring/Service and
Repair/Removal and Replacement/Valve Springs.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Locations
Oil Pressure Sender: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Locations > Page 2037
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Locations > Page 2038
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 Control Components
Engine Oil Temperature (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.
Typical Thread Type Sensor
Typical EOT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Tighten the camshaft bolt to.................................................................................................................
..........................................................85 Nm (63 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Diagrams
Timing Chain: Diagrams
Early build vehicles
NOTE: Due to the gear ratio between the reversal shaft and the balance shaft, up to 7 complete
turns of the balance shaft may be required to find the correct position.
Align the timing marks. - Install a 4 mm (0.16 in) pin to hold the shaft in place.
Late build vehicles
NOTE: Due to the gear ratio between the reversal shaft and the balance shaft, up to 7 complete
turns of the balance shaft may be required to find the correct position.
Align the timing marks.
1. Align the front balance shaft gear alignment marks with the hole in the balance shaft housing. 2.
From the rear of the balance shaft, make sure the balance shaft gear alignment mark is visible
through the hole in the balance shaft housing.
All vehicles
Install the balance shaft chain and crankshaft sprocket.
Install the crankshaft key. Position the jackshaft and crankshaft sprockets and the chain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Diagrams > Page 2049
NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong
direction can damage the bolt.
NOTE: The camshaft sprocket must turn freely on the camshaft. Do not tighten the bolt.
Loosely install the RH camshaft sprocket bolt.
Position the LH camshaft sprocket.
NOTE: The camshaft sprocket must turn freely on the camshaft. Do not tighten the bolt.
Loosely install the LH camshaft sprocket bolt.
Turn the crankshaft one revolution clockwise.
NOTICE: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will
result in incorrect timing of the engine.
NOTE: The Crankshaft TDC Timing Tool must be installed on the damper and should contact the
engine block. This positions the engine at Top Dead Center (TDC).
Install the Crankshaft TDC Timing Tool.
NOTE: Camshaft timing slots are off-center.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Diagrams > Page 2050
NOTE: Position the camshaft timing slots below centerline of camshaft.
Install the Camshaft Holding Tool and the Adapter for 303-577 on the front of the RH cylinder head.
NOTE: Leave the top 2 Camshaft Sprocket Holding Tool clamp bolts loose.
Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the rear of the RH
cylinder head.
NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong
direction can damage the bolt.
Tighten the bolts.
NOTE: Do not tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts. The camshaft
sprocket must rotate freely.
Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the front of the LH
cylinder head.
NOTE: Camshaft timing slots are off-center.
NOTE: Position the camshaft timing slots below centerline of camshaft.
Install the Camshaft Holding Tool and the Adapter for 303-577 on the front of the LH cylinder head.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Specifications
Timing Chain Tensioner: Specifications
Install a new washer and the RH timing chain tensioner. Tighten to....................................................
...................................................................................................................................................44 Nm
(32 lb-ft).
Install a new washer and the LH timing chain tensioner. Tighten to....................................................
...................................................................................................................................................44 Nm
(32 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > Hydraulic Timing Chain Tensioner - LH
Timing Chain Tensioner: Service and Repair Hydraulic Timing Chain Tensioner - LH
Hydraulic Timing Chain Tensioner - LH
Removal and Installation
1. Remove the hydraulic timing chain tensioner.
- To install, tighten to 44 Nm (32 lb-ft).
2. Remove and discard the washer.
3. To install, reverse the removal procedure.
- Install a new hydraulic timing chain tensioner washer.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > Hydraulic Timing Chain Tensioner - LH > Page 2056
Timing Chain Tensioner: Service and Repair Hydraulic Timing Chain Tensioner - RH
Hydraulic Timing Chain Tensioner - RH
Removal and Installation
1. Remove the hydraulic timing chain tensioner.
- To install, tighten to 44 Nm (32 lb-ft).
2. Remove and discard the washer.
3. To install, reverse the removal procedure.
- Install a new hydraulic timing chain tensioner washer.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications
Timing Cover: Specifications
Install the Front Cover Aligner and tighten the 5 bolts and 5 stud bolts. Tighten to.............................
..............................................................................................................................................................
.........19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2060
Timing Cover: Service and Repair
Engine Front Cover
Lower End Components
Accessory Drive Brackets
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2061
Engine Front Cover
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2062
Removal
1. Disconnect the battery ground cable.
2. Drain the cooling system.
3. Remove the crankshaft front seal. For additional information, refer to Crankshaft Front Seal See:
Seals and Gaskets/Front Crankshaft Seal/Service
and Repair.
4. Remove the nut and detach the wiring harness bracket from the front cover.
5. Remove the 5 oil pan-to-front cover bolts.
6. Disconnect the lower radiator hose.
7. Remove the bolt and the drive belt tensioner.
8. Disconnect the heater hose from the coolant pump.
9. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
10. Remove the nut and disconnect the generator B+ terminal.
11. Disconnect the generator electrical connector and detach the wiring harness retainer.
12. Remove the 3 generator bracket bolts and the generator bracket.
13. Remove the coil bracket-to-A/C compressor and power steering pump bracket bolt.
14. Remove the 4 bolts and the A/C compressor and power steering pump bracket.
15. Remove and discard the CKP sensor wiring harness retainers.
16. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
17. Disconnect the upper radiator hose from the thermostat housing.
18. Disconnect the heater hose from the thermostat housing.
19. NOTE: The bypass hose will be removed with the thermostat housing.
Release the bypass hose clamp from the coolant pump end.
20. Remove the 3 bolts and the thermostat housing.
21. NOTE: Note the positions of the stud bolts for installation reference.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2063
Remove the 10 bolts, the engine front cover and the gasket. Discard the gasket.
Installation
1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean sealing surfaces. These tools
cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of the old front cover gasket and the silicone sealer.
Clean and inspect the gasket mating surfaces. Use silicone gasket remover and metal surface prep
and a plastic scraping tool. Follow the directions on the packaging.
2. Position the front cover gasket.
NOTICE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the
directions on the packaging. Failure to follow this procedure can cause future oil leakage.
3. Apply silicone gasket and sealant to the oil pan and engine block mating surfaces.
4. Apply silicone gasket and sealant to the front cover in 2 places as shown.
5. NOTE: Make sure the stud bolts are installed in their original positions.
Position the engine front cover and install the 10 bolts.
- Tighten to 19 Nm (168 lb-in).
6. NOTE: Make sure the coolant bypass hose is attached to the coolant pump.
Position the thermostat housing and install the 3 bolts.
- Tighten to 11 Nm (97 lb-in).
7. Position the bypass hose clamp.
8. Connect the upper radiator hose to the thermostat housing.
9. Connect the heater hose to the thermostat housing.
10. Connect the ECT sensor electrical connector.
11. Install new wiring harness retainers and position the CKP sensor wiring.
12. Connect the CKP sensor electrical connector.
13. Position the A/C compressor and power steering pump bracket and install the 4 bolts.
- Tighten to 42 Nm (31 lb-ft).
14. Install the ignition coil bracket-to-A/C compressor and power steering pump bracket bolt.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2064
- Tighten to 10 Nm (89 lb-in).
15. Position the generator bracket and install the 3 bolts.
- Tighten to 42 Nm (31 lb-ft).
16. Connect the generator electrical connector and attach the wiring harness retainer.
17. Connect the generator B+ terminal and install the nut.
- Tighten to 8 Nm (71 lb-in).
18. Connect the heater hose to the coolant pump.
19. Position the accessory drive belt tensioner and install the bolt.
- Tighten to 47 Nm (35 lb-ft).
20. Connect the lower radiator hose.
21. Install the 5 cylinder block cradle-to-front cover bolts.
- Tighten to 14 Nm (124 lb-in).
22. Position the wiring harness bracket and install the nut.
- Tighten to 20 Nm (177 lb-in).
23. Install the crankshaft front seal. For additional information, refer to Crankshaft Front Seal See:
Seals and Gaskets/Front Crankshaft Seal/Service
and Repair.
24. Connect the battery ground cable.
25. Fill the engine cooling system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Description and Operation
Variable Valve Timing Actuator: Description and Operation
Variable Camshaft Timing (VCT) System
Overview
The VCT system enables rotation of the camshaft(s) relative to the crankshaft rotation as a function
of engine operating conditions. There are four 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 four 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.
The VCT system knocking and noise concerns are diagnosed in the Testing and Inspection
section. For additional information, refer to the Engine System - General Information. Verification of
incorrect VCT phasing on a warm engine operating below 1500 RPM can be isolated using a
stethoscope and by monitoring the VCTADV, VCTADVERR and VCTDC PIDs using a scan tool. If
the VCT phaser does not maintain correct valve timing, low oil pressure or oil flow restrictions are
primary possible causes. Verify correct oil pressure and flow, refer to the Engine System - General
Information.
Variable Camshaft Timing (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 indicates 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), engine coolant
temperature (ECT), engine oil temperature (EOT), CMP,
throttle position (TP), mass air flow (MAF), and CKP sensors 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Description and Operation > Page 2069
achieved. A difference between the desired and actual camshaft position represents a position
error in the PCM VCT control loop. The PCM disables the VCT and places the camshaft in a
default position if a concern is detected. A related DTC is also set when the concern is detected.
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 two 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.
VCT System
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Cover / Housing > Component Information > Service and Repair
Variable Valve Timing Cover / Housing: Service and Repair
Variable Camshaft Timing (VCT) Housing Cleaning and Inspection
1. Remove the screw and the Variable Camshaft Timing (VCT) oil control solenoid.
- To install, tighten to 5 Nm (44 lb-in).
2. Clean the mating surfaces and oil passages with metal surface prep. Follow the directions on the
packaging.
3. Inspect the VCT housing for pitting, cracks or damaged sealing surfaces. Install a new VCT
housing if damaged.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Solenoid > Component Information > Locations > VCT Solenoid 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Solenoid > Component Information > Locations > VCT Solenoid 1 > Page 2077
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Solenoid > Component Information > Diagrams > VCT Solenoid 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Solenoid > Component Information > Diagrams > VCT Solenoid 1 > Page 2080
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Solenoid > Component Information > Diagrams > Page 2081
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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications
Fuel Pressure: Specifications
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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications > Page 2086
Fuel Pressure: Testing and Inspection
Fuel System Pressure Test
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.
WARNING: 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.
WARNING: 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. Release the fuel system pressure. For additional information, refer to Fuel System Pressure
Release See: Fuel Filter/Fuel Pressure Release/Service
and Repair.
2. Disconnect the battery ground cable.
3. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. For additional information, refer
to Spring Lock Couplings See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Spring Lock
Couplings.
4. NOTE: 4.6L shown, 4.0L similar.
Install the Fuel Pressure Test Kit in line between the fuel supply tube and fuel rail.
5. NOTE: The Inertia Fuel Shutoff (IFS) switch electrical connector was disconnected during fuel
system pressure release.
Connect the IFS switch electrical connector.
6. Connect the battery ground cable.
7. 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.
8. Test the fuel system pressure to make sure it is within the specified range. For additional
information, refer to Specifications.
9. NOTE: 4.6L shown, 4.0L similar.
NOTE: 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 Fuel Pressure Test
Kit and relieve the fuel system pressure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications > Page 2087
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 Hot Idle ............................................................................................................
.......................................................................................... 750 - 820 RPM
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Intake Air System Components Exploded View
Air Filter Element: Service and Repair Intake Air System Components - Exploded View
Intake Air System Components - Exploded View
Coolant Expansion Tank
Intake Air System Components (4.0L SOHC)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Intake Air System Components Exploded View > Page 2096
Intake Air System Components - 4.6L (3V)
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Intake Air System Components Exploded View > Page 2097
Air Filter Element: Service and Repair Air Cleaner Element
Air Cleaner Element
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 element.
6. NOTE: Clean the inside of the ACL tray.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
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. 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.
NOTE: It may be necessary to reposition the lower end of the door jam weatherstripping to remove
the front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the Inertia Fuel Shutoff (IFS) switch electrical connector.
4. Start the engine and allow it to idle until it stalls.
5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail
pressure has been released.
6. Turn the ignition switch to the OFF position.
7. When the fuel system service is complete, reconnect the IFS switch electrical connector.
8. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before
starting the engine.
9. Start the vehicle and check the fuel system for leaks.
10. Install the front passenger side interior kick panel.
11. Install the front passenger door frame scuff plate.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Firing Order: Specifications
Firing order...........................................................................................................................................
..................................................................1-4-2-5-3-6
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > System Information > Specifications
Ignition Timing: Specifications
Base ignition timing................................................................................................................10
degrees Before Top Dead Center (BTDC), Non-adjustable
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Service and Repair
Ignition Cable: Service and Repair
Spark Plug Wires
Removal and Installation
1. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible
damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. For additional
information, refer to the Cylinder-to-Coil Terminal Relationship, Engine Ignition See: Powertrain
Management/Ignition System/Description and Operation in the Description and Operation.
Squeeze the locking tabs and twist while pulling upward to disconnect the 6 spark plug wires from
the ignition coil.
2. Detach the spark plug wires from the spark plug wire retainers.
3. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible
damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct spark plug.
With a twisting motion, use the Spark Plug Wire Remover to pull the spark plug wires from the
spark plugs.
4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Gap
Spark Plug: Specifications Gap
Item.......................................................................................................................................................
...............................................................Specification
Spark Plug Gap....................................................................................................................................
....................................1.32-1.42 mm (0.052-0.056 in)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Gap > Page 2115
Spark Plug: Specifications Torque Specifications
Spark plugs...........................................................................................................................................
........................................................17 Nm (150 lb-in)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2116
Spark Plug: Application and ID
Item.......................................................................................................................................................
...............................................................Specification
Spark Plug type....................................................................................................................................
....................................................................AGSF24N
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2117
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.
- Install a new 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.
5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine
damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized
installation of a heli-coil insert in place of the spark plug threads. Install a new spark plug.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2118
6. Inspect for overheating, identified by white or light gray spots and 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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View
Spark Plug: Service and Repair Engine Ignition Components - Exploded View
Engine Ignition Components - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View > Page 2121
Spark Plug: Service and Repair Spark Plugs
Spark Plugs
Removal and Installation
1. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible
damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct spark plug. Refer to the Cylinder-to-Coil
Terminal Relationship, Engine Ignition See: Powertrain Management/Ignition System/Description
and Operation in the Description and Operation.
With a twisting motion, use the Spark Plug Wire Remover to pull the spark plug wire from the spark
plug.
2. NOTE: Use compressed air to remove any foreign material from the spark plug wells before
removing the spark plugs.
Remove the spark plugs.
- To install, tighten to 17 Nm (150 lb-in).
3. Use a suitable spark plug gap tool to check and adjust the spark plug gap.
4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
Compression Check: Specifications
Compression Test - Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart.
Compression Pressure Limit Chart
If one or more cylinders reads 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 within 75% of the highest reading.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 2125
Compression Check: Testing and Inspection
Engine
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 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
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the
pistons in the low-reading cylinders. Repeat the
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 2126
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 within 75% of the highest reading.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
Water Pump: Specifications
Install a new gasket, the coolant pump and the 13 bolts. Tighten to....................................................
..................................................................................................................................................10 Nm
(89 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Page 2130
Water Pump: Service and Repair
Coolant Pump - 4.0L SOHC
Removal and Installation
1. Drain the engine cooling system. For additional information, refer to Cooling System Draining,
Filling and Bleeding See: Cooling System/Service
and Repair/Procedures/Cooling System Draining, Filling and Bleeding.
2. Remove the cooling fan. For additional information, refer to Cooling Fan See: Cooling
System/Radiator Cooling Fan/Fan Blade/Service and
Repair.
3. Remove the accessory drive belt.
4. Remove the bolts and the coolant pump pulley.
- To install, tighten to 25 Nm (18 lb-ft).
5. Release the clamp and disconnect the coolant pump bypass hose.
6. Release the clamp and disconnect the heater hose.
7. Release the clamp and disconnect the lower radiator hose.
8. Remove the bolts, the coolant pump and the gasket.
- To install, tighten to 10 Nm (89 lb-in).
9. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools
cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of the old gasket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Page 2131
Clean the mating surfaces with a plastic scraper and metal surface prep. Follow the directions on
the packaging.
10. To install, reverse the removal procedure.
- Install a new coolant pump gasket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications
Coolant: Specifications
Engine Coolant
...................................................................................................................................................
Motorcraft Premium Gold Engine Coolant Note: Add the coolant type originally equipped in your
vehicle.
Ford Part Number ................................................................................................................................
................................................................... VC-7-B Ford Specification ...............................................
.....................................................................................................................................
WSS-M97B51-A1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Accessory Drive Belt
Generator
Coolant Crossover Manifold Assembly
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information >
Service and Repair > Page 2139
Removal and Installation
1. Drain the engine cooling system. For additional information, refer to Cooling System Draining,
Filling and Bleeding See: Service and
Repair/Procedures/Cooling System Draining, Filling and Bleeding.
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).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information >
Service and Repair > Page 2140
- Install new gaskets.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Technical Service Bulletins > Customer Interest for Coolant Reservoir: > 09-11-12 > Jun > 09 > Cooling System - Coolant
Leaks From The Reservoir
Coolant Reservoir: Customer Interest Cooling System - Coolant Leaks From The Reservoir
TSB 09-11-12
06/15/09
COOLANT EXPANSION TANK LEAKS - 4.0L ENGINE
FORD: 2006-2009 Explorer 2007-2009 Explorer Sport Trac
MERCURY: 2006-2009 Mountaineer
ISSUE Some 2006-2009 Explorer, Mountaineer and 2007-2009 Explorer Sport Trac vehicles
equipped with 4.0L engine may experience coolant leaking from the coolant expansion tank. This
may be due to cracks that develop in the coolant expansion tank at the radiator mounting bolt
locations.
ACTION Replace the coolant expansion tank. Follow the service procedure steps to correct the
condition.
SERVICE PROCEDURE
1. Allow the engine to cool before removing the coolant expansion tank.
2. Disconnect the coolant overflow hose.
3. Remove the bolts and the coolant expansion tank. (Figure 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Technical Service Bulletins > Customer Interest for Coolant Reservoir: > 09-11-12 > Jun > 09 > Cooling System - Coolant
Leaks From The Reservoir > Page 2149
4. Make sure the J clips in the upper radiator mounting boss sit flush. (Figure 2)
5. Install the updated coolant expansion tank.
6. Use the new bolt fasteners.
7. Torque to 43 lb-in (4.8 N.m).
8. Connect the coolant overflow hose.
9. Verify proper coolant level.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
091112A 2006-2009 Explorer, 0.4 Hr.
Mountaineer, 2007-2009 Explorer Sport Trac: Replace Coolant Expansion Tank(Do Not Use With
8080A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
8A080 01
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Coolant Reservoir: > 09-11-12 > Jun > 09 > Cooling System
- Coolant Leaks From The Reservoir
Coolant Reservoir: All Technical Service Bulletins Cooling System - Coolant Leaks From The
Reservoir
TSB 09-11-12
06/15/09
COOLANT EXPANSION TANK LEAKS - 4.0L ENGINE
FORD: 2006-2009 Explorer 2007-2009 Explorer Sport Trac
MERCURY: 2006-2009 Mountaineer
ISSUE Some 2006-2009 Explorer, Mountaineer and 2007-2009 Explorer Sport Trac vehicles
equipped with 4.0L engine may experience coolant leaking from the coolant expansion tank. This
may be due to cracks that develop in the coolant expansion tank at the radiator mounting bolt
locations.
ACTION Replace the coolant expansion tank. Follow the service procedure steps to correct the
condition.
SERVICE PROCEDURE
1. Allow the engine to cool before removing the coolant expansion tank.
2. Disconnect the coolant overflow hose.
3. Remove the bolts and the coolant expansion tank. (Figure 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Coolant Reservoir: > 09-11-12 > Jun > 09 > Cooling System
- Coolant Leaks From The Reservoir > Page 2155
4. Make sure the J clips in the upper radiator mounting boss sit flush. (Figure 2)
5. Install the updated coolant expansion tank.
6. Use the new bolt fasteners.
7. Torque to 43 lb-in (4.8 N.m).
8. Connect the coolant overflow hose.
9. Verify proper coolant level.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
091112A 2006-2009 Explorer, 0.4 Hr.
Mountaineer, 2007-2009 Explorer Sport Trac: Replace Coolant Expansion Tank(Do Not Use With
8080A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
8A080 01
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Technical Service Bulletins > Page 2156
Coolant Reservoir: Service and Repair
Coolant Expansion Tank
NOTICE: 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 (V6-4.0L (2009))
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
Engine Control Components
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):
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).
FCV Duty Cycle Output From PCM (Negative Duty Cycle)
For relay controlled fans:
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
cooling fan speed is controlled by a combination of these outputs. Refer to the following table.
2.0L Focus (with A/C): PCM FC Output State For Cooling Fan Speeds
2.5L Escape: PCM FC Output State For Cooling Fan Speeds
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
Fan Speed Sensor (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. For additional information on the cooling fan clutch, refer to the Cooling Fan Clutch.
Cooling Fan Clutch with Fan Speed Sensor (FSS)
Cooling Fan Clutch with FSS
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (ACL) outlet pipe.
All vehicles
2. Remove the coolant expansion tank. For additional information, refer to Coolant Expansion Tank
See: Coolant Reservoir/Service and Repair.
3. Remove the bolt and position the power steering fluid reservoir aside.
- To install, tighten to 10 Nm (89 lb-in).
4. Remove the 2 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).
7. NOTICE: 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 Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the cooling fan.
- To install, tighten to 55 Nm (41 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Service and Repair > Page 2167
8. Remove the 4 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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Diagrams > Page 2171
Fan Clutch: Description and Operation
Engine Control Components
Cooling Fan Clutch
The cooling fan clutch is an electrically actuated viscous clutch that consists of three 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.
Cooling Fan Clutch with Fan Speed Sensor (FSS)
Cooling Fan Clutch with Fan Speed Sensor (FSS)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Diagrams > Page 2172
Fan Clutch: Tools and Equipment
Fan Clutch Holding Tool AST tool# 8005
Allows the technician to hold the water pump pulleuy in place while loosening the radiator fan.
2009 Suggested user price: $41.20
Assenmacher Specialty Tools 1 800 525 2943
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2177
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2178
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Engine Control Components
Engine Coolant Temperature (ECT) Sensor
The ECT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases, and the resistance
increases as the temperature decreases. The varying resistance changes the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor
determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage
minus the voltage drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The PCM uses the ECT input for fuel
control and for cooling fan control. There are three types of ECT sensors, threaded, push-in, and
twist-lock. The ECT sensor is located in an engine coolant passage.
Typical Thread Type Sensor
Typical Thread Type ECT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2179
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature (ECT) Sensor - 4.0L SOHC
Removal and Installation
1. Drain the cooling system.
2. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
3. Remove the clip and the ECT sensor.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Locations > Page 2183
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Locations > Page 2184
Engine Temperature Sensor: Description and Operation
Engine Control Components
Cylinder Head Temperature (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. For
additional information, refer to Powertrain Control Software See: Powertrain
Management/Computers and Control Systems/Description and Operation/Powertrain Control
Software for Fail-Safe Cooling Strategy.
Typical CHT Sensor
Typical CHT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (ACL) outlet pipe.
All vehicles
2. Remove the coolant expansion tank. For additional information, refer to Coolant Expansion Tank
See: Coolant Reservoir/Service and Repair.
3. Remove the bolt and position the power steering fluid reservoir aside.
- To install, tighten to 10 Nm (89 lb-in).
4. Remove the 2 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).
7. NOTICE: 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 Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the cooling fan.
- To install, tighten to 55 Nm (41 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Service and Repair > Page 2188
8. Remove the 2 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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component
Information > Service and Repair
Heater Control Valve: Service and Repair
Heater Control Valve
Removal and Installation
Vehicles with 4.0L and oil cooler, without auxiliary climate control
1. With the vehicle in NEUTRAL, position it on a hoist.
All vehicles
2. Drain the engine coolant.
3. Disconnect the 2 inlet and outlet heater hose clamps.
4. Disconnect the heater control valve vacuum hose.
Vehicles with 4.0L and oil cooler, without auxiliary climate control
5. Remove the heater control valve bolt.
All vehicles
6. Remove the heater control valve.
7. NOTE: Lubricate the coolant hoses with plain water only if needed.
To install, reverse the removal procedure.
8. Fill the engine cooling system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Testing and Inspection > Heater Core
Heater Core: Testing and Inspection Heater Core
Climate Control System
Component Tests
Heater Core
1. NOTE: 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: See: Heater Core - Plugged
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Testing and Inspection > Heater Core > Page 2196
Heater Core: Testing and Inspection Heater Core - Plugged
Climate Control System
Component Tests
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, using a suitable temperature
measuring device, check 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Testing and Inspection > Heater Core > Page 2197
Heater Core: Testing and Inspection Heater Core - Pressure Test
Climate Control System
Component Tests
Heater Core - Pressure Test
Use the Pressure Test Kit 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 Pressure Test Kit 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 Pressure Test Kit 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. See: Heater Core - Bench Test
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Testing and Inspection > Heater Core > Page 2198
Heater Core: Testing and Inspection Heater Core - Bench Test
Climate Control System
Component Tests
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
from the Pressure Test Kit to the adapter.
4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water.
5. If a leak is observed, replace the heater core.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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. For additional information, refer to Heater
Core And Evaporator Core Housing See:
Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/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.
8. Remove the 3 heater tube cover screws.
9. Remove the heater tube cover.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core > Page 2201
10. Remove the heater tube seal.
11. Remove the 4 heater core cover screws.
12. Remove the heater core cover.
13. Remove the heater core.
14. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core > Page 2202
Heater Core: Service and Repair Auxiliary Heater Core
Auxiliary Heater Core
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core > Page 2203
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.
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 heater core and evaporator core housing bolts and auxiliary heater core
and evaporator core 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core > Page 2204
18. To install, reverse the removal procedure.
- Lubricate the coolant hoses with plain water only if needed.
19. Fill the engine cooling system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Customer Interest for Heater Hose: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL
ON/DTC P2135 Set
Heater Hose: Customer Interest A/C, Engine Controls - MIL ON/DTC P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Customer Interest for Heater Hose: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL
ON/DTC P2135 Set > Page 2213
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 09-22-4 > Nov > 09 > A/C, Engine Controls MIL ON/DTC P2135 Set
Heater Hose: All Technical Service Bulletins A/C, Engine Controls - MIL ON/DTC P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 09-22-4 > Nov > 09 > A/C, Engine Controls MIL ON/DTC P2135 Set > Page 2219
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair
Radiator: Service and Repair
Radiator
Removal and Installation
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling
and Bleeding See: Service and
Repair/Procedures/Cooling System Draining, Filling and Bleeding.
Vehicles equipped with a 4.6L (3V) engine
3. Remove the Air Cleaner (ACL) outlet pipe.
All vehicles
4. Remove the coolant expansion tank. For additional information, refer to Coolant Expansion Tank
See: Coolant Reservoir/Service and Repair.
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 and position the air deflector aside.
11. Remove the 2 latch assemblies from the transmission cooler tubes.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Page 2223
12. Using the Transmission Cooler Line Disconnect Tool, disconnect the 2 transmission cooler
tubes.
13. Remove the 2 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).
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. NOTICE: 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 Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the cooling fan.
- To install, tighten to 55 Nm (41 lb-ft).
17. Remove the 2 bolts and the lower fan shroud.
18. Detach the A/C tube from the retainer on the radiator support bracket.
19. NOTE: LH shown RH similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Page 2224
Remove the 2 radiator support bracket-to-radiator support bolts.
- To install, tighten to 15 Nm (133 lb-in).
20. Lift the radiator and A/C condenser assembly off the frame supports and move the assembly
toward the front of the engine.
21. Remove the radiator top seal.
22. NOTE: Do not remove the A/C condenser seals.
NOTE: LH shown RH similar.
Deflect the A/C condenser seals and remove the 2 A/C condenser-to-radiator support bracket
bolts.
- To install, tighten to 12 Nm (106 lb-in).
23. Lift the A/C condenser off the supports and move the A/C condenser toward the front of the
vehicle.
24. Remove the radiator and the radiator support brackets as an assembly.
- Move the LH radiator support bracket past the ABS module before removing the radiator from the
vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Page 2225
25. Remove the 4 bolts and separate the 2 radiator support brackets and the radiator.
- To install, tighten to 12 Nm (106 lb-in).
26. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
Fan Speed Sensor (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. For additional information on the cooling fan clutch, refer to the Cooling Fan Clutch.
Cooling Fan Clutch with Fan Speed Sensor (FSS)
Cooling Fan Clutch with FSS
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 2234
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 2235
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Engine Control Components
Engine Coolant Temperature (ECT) Sensor
The ECT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases, and the resistance
increases as the temperature decreases. The varying resistance changes the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor
determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage
minus the voltage drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The PCM uses the ECT input for fuel
control and for cooling fan control. There are three types of ECT sensors, threaded, push-in, and
twist-lock. The ECT sensor is located in an engine coolant passage.
Typical Thread Type Sensor
Typical Thread Type ECT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 2236
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature (ECT) Sensor - 4.0L SOHC
Removal and Installation
1. Drain the cooling system.
2. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
3. Remove the clip and the ECT sensor.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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
2240
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
2241
Engine Temperature Sensor: Description and Operation
Engine Control Components
Cylinder Head Temperature (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. For
additional information, refer to Powertrain Control Software See: Powertrain
Management/Computers and Control Systems/Description and Operation/Powertrain Control
Software for Fail-Safe Cooling Strategy.
Typical CHT Sensor
Typical CHT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications
Thermostat: Specifications
Thermostat Opening Temperature
Starts to open.......................................................................................................................................
...................................................90-94°C (194-201°F) Fully open.......................................................
...................................................................................................................................................106°C
(223°F)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Service and Repair > Thermostat and Thermostat Housing - Exploded View
Thermostat: Service and Repair Thermostat and Thermostat Housing - Exploded View
Thermostat and Thermostat Housing - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Service and Repair > Thermostat and Thermostat Housing - Exploded View > Page 2247
Thermostat: Service and Repair Thermostat
Thermostat - 4.0L SOHC
Removal and Installation
1. Drain the engine cooling system. For additional information, refer to Cooling System Draining,
Filling and Bleeding See: Service and
Repair/Procedures/Cooling System Draining, Filling and Bleeding.
2. Release the clamp and disconnect the upper radiator hose from the thermostat housing cover.
3. Remove the bolts and the thermostat housing cover.
- To install, tighten to 10 Nm (89 lb-in).
4. Remove the thermostat.
5. NOTE: Inspect the thermostat housing cover O-ring seal. Install a new O-ring seal if necessary.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications
Water Pump: Specifications
Install a new gasket, the coolant pump and the 13 bolts. Tighten to....................................................
..................................................................................................................................................10 Nm
(89 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 2251
Water Pump: Service and Repair
Coolant Pump - 4.0L SOHC
Removal and Installation
1. Drain the engine cooling system. For additional information, refer to Cooling System Draining,
Filling and Bleeding See: Service and
Repair/Procedures/Cooling System Draining, Filling and Bleeding.
2. Remove the cooling fan. For additional information, refer to Cooling Fan See: Radiator Cooling
Fan/Fan Blade/Service and Repair.
3. Remove the accessory drive belt.
4. Remove the bolts and the coolant pump pulley.
- To install, tighten to 25 Nm (18 lb-ft).
5. Release the clamp and disconnect the coolant pump bypass hose.
6. Release the clamp and disconnect the heater hose.
7. Release the clamp and disconnect the lower radiator hose.
8. Remove the bolts, the coolant pump and the gasket.
- To install, tighten to 10 Nm (89 lb-in).
9. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools
cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of the old gasket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 2252
Clean the mating surfaces with a plastic scraper and metal surface prep. Follow the directions on
the packaging.
10. To install, reverse the removal procedure.
- Install a new coolant pump gasket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
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 (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 two 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 (PZEVs) use three HO2Ss. The stream 1 sensor (HO2S11) located before the
catalyst is used for primary fuel control, the stream 2 sensor (HO2S12) is used to monitor the
light-off catalyst, and the stream 3 sensor (HO2S13) located after the catalyst is used for long term
fuel trim control to optimize catalyst efficiency (fore aft oxygen sensor control).
V-Engines
V-Engines
In-Line Engines
In-Line Engines
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 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 three way catalytic converter (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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 2257
catalyst.
Three Way Catalytic Converter (TWC) Conversion Efficiency
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.
TWC Conversion Efficiency Chart
TWC Conversion Efficiency Chart
Exhaust System
The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the
atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the
catalytic converter through the front exhaust pipe. 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 three HO2Ss 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.
Typical Bank 1 Catalyst 2 H2OS Configuration
Typical Bank 1 Catalyst 2 HO2S Configuration
Typical Bank 1 Catalyst 3 H2OS Configuration
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 2258
Typical Bank 1 Catalyst 3 HO2S Configuration
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 two light off catalysts,
forming a Y pipe configuration. For an exact configuration of the catalyst and exhaust system for a
specific vehicle, refer to the Exhaust System for the exhaust system exploded view.
Three Way Catalytic (TWC) Converter
The TWC contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The
TWC 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. For
additional information on the HO2S, refer to Engine Control Components See: Powertrain
Management/Computers and Control Systems/Description and Operation/Engine Control
Components.
Muffler
Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase
the life of the product. The muffler reduces the level of noise produced by the engine, and also
reduces the noise produced by exhaust gases as they travel from the catalytic converter to the
atmosphere.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 2259
Catalytic Converter: Service and Repair
Exhaust System - Exploded View
4.0L Explorer Sport Trac
NOTE: Vehicle body removed for clarity.
4.6L Explorer Sport Trac
NOTE: Vehicle body removed for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 2260
4.0L Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
NOTE: Premier exhaust shown, standard exhaust similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 2261
4.6L Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
NOTE: Premier exhaust shown, standard exhaust similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 2262
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Specifications
Exhaust Manifold: Specifications
Install 6 new RH exhaust manifold studs. Tighten to............................................................................
........................................................................................................................12 Nm (106 lb-in).
Install a new gasket, the RH exhaust manifold and the 6 new nuts. Tighten to...................................
..............................................................................................................................................................
......22 Nm (16 lb-ft).
Install 6 new LH exhaust manifold studs. Tighten to............................................................................
........................................................................................................................12 Nm (106 lb-in).
Install a new gasket, the LH exhaust manifold and the 6 new nuts. Tighten to....................................
..............................................................................................................................................................
......22 Nm (16 lb-ft)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Procedures
Exhaust Manifold: Procedures
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 Straightedge and a Feeler Gauge Set, 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 (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Procedures > Page 2268
Exhaust Manifold: Removal and Replacement
Exhaust Manifold - LH
Exhaust Manifold - LH
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the 4 exhaust manifold-to-dual converter Y-pipe nuts and position the dual converter
Y-pipe aside.
- Discard the nuts.
3. Remove the 6 nuts, the LH exhaust manifold and the gasket.
- Discard the nuts and the gasket.
4. Remove and discard the 6 LH exhaust manifold studs.
Installation
1. Inspect the LH exhaust manifold gasket surfaces for flatness.
2. Install 6 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
3. Position a new gasket, the LH exhaust manifold and install 6 new nuts.
- Tighten to 22 Nm (16 lb-ft).
4. Position the dual converter Y-pipe and install 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).
Exhaust Manifold - RH
Exhaust Manifold - RH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Procedures > Page 2269
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the EGR tube.
3. Remove the 4 exhaust manifold-to-dual converter Y-pipe nuts and position the dual converter
Y-pipe aside.
- Discard the nuts.
4. Remove the 6 nuts, the RH exhaust manifold and the gasket.
- Discard the nuts and the gasket.
5. Remove and discard the 6 RH exhaust manifold studs.
Installation
1. Inspect the RH exhaust manifold gasket surfaces for flatness.
2. Install 6 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
3. Position a new gasket, the RH exhaust manifold and install 6 new nuts.
- Tighten to 22 Nm (16 lb-ft).
4. Position the dual converter Y-pipe and install 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).
5. Install the EGR tube.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Exhaust System - Exploded View
Exhaust Pipe: Service and Repair Exhaust System - Exploded View
Exhaust System - Exploded View
4.0L Explorer Sport Trac
NOTE: Vehicle body removed for clarity.
4.6L Explorer Sport Trac
NOTE: Vehicle body removed for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Exhaust System - Exploded View > Page 2274
4.0L Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
NOTE: Premier exhaust shown, standard exhaust similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Exhaust System - Exploded View > Page 2275
4.6L Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
NOTE: Premier exhaust shown, standard exhaust similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Exhaust System - Exploded View > Page 2276
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Exhaust System - Exploded View > Page 2277
Exhaust Pipe: Service and Repair Exhaust Y-Pipe - Dual Catalytic Converter
Exhaust Y-Pipe - Dual Catalytic Converter
Removal
NOTICE: 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.
2. Using a suitable jack, support the exhaust system.
3. Disconnect the Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS)
electrical connectors.
4. Remove the 2 exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts, 2 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 tighten 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
4 new nuts to stiffen the joint enough to maintain position.
- 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, 2 bolts and 2
new nuts.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Exhaust System - Exploded View > Page 2278
- Tighten to 40 Nm (30 lb-ft).
3. NOTE: RH shown, LH similar.
Tighten the 4 new 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 CMS 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. For additional information, refer the Exhaust System Alignment See: Service
and Repair/Exhaust System Alignment.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Exhaust System - Exploded View > Page 2279
Exhaust Pipe: Service and Repair Tailpipe
Tailpipe
Removal
NOTICE: 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.
2. Loosen the muffler assembly-to-tail pipe Torca(R) clamp.
3. Disconnect the rubber isolator and remove the tail pipe.
Installation
1. Position the tail pipe and connect the rubber isolator.
2. NOTE: Using an abrasive pad, clean the muffler assembly-to-tail pipe surface area of any rust.
Position the muffler assembly-to-tail pipe and make sure the tab on the muffler assembly is seated
inside the notch on the tail pipe 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. For additional information, refer the Exhaust System Alignment See: Service
and Repair/Exhaust System Alignment.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Exhaust System - Exploded View
Muffler: Service and Repair Exhaust System - Exploded View
Exhaust System - Exploded View
4.0L Explorer Sport Trac
NOTE: Vehicle body removed for clarity.
4.6L Explorer Sport Trac
NOTE: Vehicle body removed for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Exhaust System - Exploded View > Page 2284
4.0L Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
NOTE: Premier exhaust shown, standard exhaust similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Exhaust System - Exploded View > Page 2285
4.6L Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
NOTE: Premier exhaust shown, standard exhaust similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Exhaust System - Exploded View > Page 2286
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Exhaust System - Exploded View > Page 2287
Muffler: Service and Repair Muffler
Muffler
Removal
All vehicles
NOTICE: 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.
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, the muffler inlet pipe must be cut.
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, the muffler inlet pipe must be cut.
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.
All vehicles
5. Loosen the muffler assembly-to-tail pipe Torca(R) clamp.
6. Remove the 2 exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts, 2 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Exhaust System - Exploded View > Page 2288
All vehicles
1. Position the muffler assembly and connect the rubber isolators.
2. NOTE: Using an abrasive pad, clean the muffler assembly-to-tail pipe surface area of any rust.
Position the muffler assembly-to-tail pipe and make sure the tab on the muffler assembly is seated
inside the notch on the tail pipe 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. 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Exhaust System - Exploded View > Page 2289
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, 2 bolts and 2
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. For additional information, refer the Exhaust System Alignment See: Service
and Repair/Exhaust System Alignment.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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), which delivers 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 torque-based 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 two 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. 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 one reference voltage and one signal return circuit between the PCM and the ETB. The
reference voltage and the signal return circuits are shared with the reference voltage and signal
return circuits used by the accelerator pedal position (APP) sensor. There are also two throttle
position (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. For additional
information on the APP sensor, refer to Engine Control Components See: Computers and Control
Systems/Description and Operation/Engine Control Components.
Electronic Throttle Control (ETC) System Strategy
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)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 2296
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 two 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.
ETC System With A 3-Track APP Sensor Failure Mode And Effects Management:
a - ETC illuminates or displays a message on the message center immediately; MIL illuminates
after 2 driving cycles
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 2297
ETC System With A 2-Track APP Sensor Failure Mode And Effects Management:
Electronic Throttle Monitor Operation:
a - Monitor execution is continuous. Monitor false detection duration is less than 1 second to
register a concern.
APP and TP Sensor Inputs
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 2298
Accelerator Pedal Position (APP) Sensor Check:
Correlation and range/performance - sensor disagreement between processors internal to the
PCM. Monitor execution is continuous. Monitor false detection duration is less than 1 second to
register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions for additional
DTC information.
Throttle Position (TP) Sensor Check:
a - Correlation and range/performance - sensor disagreement between processors internal to the
PCM, TP inconsistent with requested throttle plate position. Monitor execution is continuous.
Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic
Trouble Code (DTC) Charts and Descriptions for additional DTC information.
Electronic Throttle Actuator Control (TAC) Output
Electronic TAC Operation Check:
a - Note: For all DTCs, in addition to the MIL, the powertrain malfunction indicator (wrench) is on for
the concern that caused the FMEM action. Monitor execution is continuous. Monitor false detection
duration is less than 5 seconds to register a concern.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift
Engine Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
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Bulletins > Customer Interest for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift > Page 2307
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift > Page 2308
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
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Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift
Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
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(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift > Page 2315
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
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Bulletins > Page 2316
Engine Control Module: Locations
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Bulletins > Page 2318
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Bulletins > Page 2319
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Bulletins > Page 2320
Engine Control Module: Diagrams
C175B Part 1
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Bulletins > Page 2321
C175B Part 2
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Bulletins > Page 2322
C175E Part 1
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Page 2323
C175E Part 2
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Page 2324
C175E Part 3
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C175T Part 1
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C175T Part 2
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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 DTC P1635 or
P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware
or parameter changes made to the vehicle since production. Failure to carry out this procedure
properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle
ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID
Block and also under Making Changes to the PCM Calibration. The VID block contains many items
used by the strategy for a variety of functions. Some of these items include the vehicle identification
number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the
presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual
shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID
block is displayed on the scan tool.
When changing items in the VID block, the strategy places range limits on certain items such as
tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this
limit is reached, the scan tool displays a message indicating the need to flash the PCM again to
reset the VID block.
On selected vehicles equipped with permanent DTC reporting capabilities, neutral profile correction
should be learned after a PCM replacement in order to activate the misfire monitor. This can be
accomplished using the Misfire Monitor Neutral Profile Learn function on the scan tool.
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.
Neutral Profile Correction
In order for the misfire detection system to function properly, any mechanical inaccuracies in the
crankshaft position (CKP) sensor must be learned by the PCM. This information is stored in
non-volatile memory (NVM) in the PCM. It is not cleared when the keep alive memory (KAM) is
reset.
Neutral profile learning is accomplished using the scan tool any time a PCM is replaced. It should
also be relearned any time the CKP sensor is replaced or major engine repairs have been
completed.
To determine if the neutral profile learning has been completed, check the MP_LRN parameter
identification (PID) using the scan tool. The PID should read YES if the neutral profile learning has
been completed. If the PID reads NO, complete the neutral profile learning prior to diagnosing any
misfire DTCs.
Programming the VID Block for a Replacement PCM
The VID block on a replacement PCM is blank and requires programming. There are two
procedures available. The first is an automatic data transfer from the old PCM to the new PCM,
and the second is manual data entry into the new PCM.
Automatic data transfer 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 be downloaded to the new PCM after it has been installed.
Carry out manual data entry if the old PCM 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 programmed PCM 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
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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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Procedures > Page 2330
Engine Control Module: Removal and Replacement
Powertrain Control Module (PCM)
A/C Tube Brackets
PCM
Removal
All vehicles
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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 (PMI) procedure. See: Computers and Control
Systems/Information Bus/Testing and Inspection/Programming and Relearning
Vehicles equipped with a 4.6L (3V) engine
2. Remove the Air Cleaner (ACL).
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 2 bolts and the PCM.
Installation
All vehicles
1. Install the PCM and the 2 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.
- Tighten to 7 Nm (62 lb-in).
Vehicles equipped with a 4.6L (3V) engine
4. Install the ACL.
All vehicles
5. Restore the module configuration. Carry out the module configuration restore steps of the
Programmable Module Installation (PMI) procedure.
See: Computers and Control Systems/Information Bus/Testing and Inspection/Programming and
Relearning
6. Reprogram the Passive Anti-Theft System (PATS). Carry out the Parameter Reset procedure.
See: Accessories and Optional Equipment/Antitheft
and Alarm Systems/Testing and Inspection/Programming and Relearning/Passive Anti-Theft
System (PATS) Parameter Reset
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Page 2335
Main Relay (Computer/Fuel System): Testing and Inspection
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Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Fuel Pump
Driver Module
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Fuel Pump Control Unit: Service and Repair
Fuel Pump Driver Module (FPDM) - Explorer, Mountaineer
Removal and Installation
1. Remove the RH rear quarter trim panel.
2. Disconnect the Fuel Pump Driver Module (FPDM) electrical connector.
3. Remove the 2 bolts and the FPDM.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
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Fuel Pump Relay: Testing and Inspection
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Page 2358
Main Relay (Computer/Fuel System): Testing and Inspection
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Page 2359
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Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
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Page 2365
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Page 2366
Accelerator Pedal Position Sensor: Description and Operation
Engine Control Components
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
There are two 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 two
pedal position signals make sure the PCM receives a correct input even if one 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 two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six
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 (TP) 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. For additional information, refer
to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic
Throttle Control Module/Description and Operation.
2-Track APP Sensor
Typical 2-Track APP Sensor
3-Track APP Sensor
There are three 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 three pedal position signals make sure the PCM
receives a correct input even if one 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 two reference voltage circuits, two signal
return circuits, and three signal circuits (a total of seven 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. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description
and Operation.
3-Track APP Sensor
Typical 3-Track APP Sensor
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Air Flow Meter/Sensor: Locations
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2371
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2372
Air Flow Meter/Sensor: Description and Operation
Engine Control Components
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 (TCC) 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 IAT sensor.
The hot wire electronic sensing element must be replaced as an assembly. Replacing only the
element may change the air flow calibration.
Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT
Sensor Wire Where Applicable) Terminals
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
Typical Mass Air Flow (MAF) Sensor
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Typical Drop-in Mass Air Flow (MAF) Sensor
Typical Drop-in Mass Air Flow (MAF) Sensor
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Air Flow Meter/Sensor: Service and Repair
Mass Air Flow (MAF) Sensor - 4.0L SOHC
Removal and Installation
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the 2 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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Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft
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Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Position Sensor > Page 2383
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft
Position Sensor > Page 2384
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page
2385
Camshaft Position Sensor: Description and Operation
Engine Control Components
Camshaft Position (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 two CMP sensors are equipped with variable camshaft timing (VCT). The second
sensor is used to identify the position of the camshaft on bank 2.
There are two types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin
Hall-effect type sensor.
Typical Variable Reluctance CMP Sensor
Typical Variable Reluctance CMP Sensor
Typical Hall-effect CMP Sensor
Typical Hall-effect CMP Sensor
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2386
Camshaft Position Sensor: Service and Repair
Camshaft Position (CMP) Sensor - 4.0L SOHC
Removal and Installation
1. Disconnect the Camshaft Position (CMP) sensor electrical connector.
2. Remove the bolt and the CMP sensor.
- To install, tighten to 6 Nm (53 lb-in).
3. To install, reverse the removal procedure.
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Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation
Clutch Switch: Description and Operation
Engine Control Components
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.
Typical Clutch Pedal Position (CPP) Switch
Typical Clutch Pedal Position (CPP) Switch
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Information > Locations > Page 2394
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Engine Control Components
Engine Coolant Temperature (ECT) Sensor
The ECT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases, and the resistance
increases as the temperature decreases. The varying resistance changes the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor
determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage
minus the voltage drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The PCM uses the ECT input for fuel
control and for cooling fan control. There are three types of ECT sensors, threaded, push-in, and
twist-lock. The ECT sensor is located in an engine coolant passage.
Typical Thread Type Sensor
Typical Thread Type ECT Sensor
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Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature (ECT) Sensor - 4.0L SOHC
Removal and Installation
1. Drain the cooling system.
2. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
3. Remove the clip and the ECT sensor.
4. To install, reverse the removal procedure.
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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2399
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2400
Crankshaft Position Sensor: Diagrams
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
2402
Crankshaft Position Sensor: Description and Operation
Engine Control Components
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.
Typical Crankshaft Position (CKP) Sensor
Typical Crankshaft Position (CKP) Sensor
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2403
Crankshaft Position Sensor: Service and Repair
Crankshaft Position (CKP) Sensor - 4.0L SOHC
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
3. Remove the 2 bolts and the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. NOTE: Be sure the sensor wiring is routed away from the battery cable.
To install, reverse the removal procedure.
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2407
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2408
Engine Temperature Sensor: Description and Operation
Engine Control Components
Cylinder Head Temperature (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. For
additional information, refer to Powertrain Control Software See: Computers and Control
Systems/Description and Operation/Powertrain Control Software for Fail-Safe Cooling Strategy.
Typical CHT Sensor
Typical CHT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation
Fuel Level Sensor: Description and Operation
Engine Control Components
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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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel
Tank and Filler Pipe - Exploded View
Fuel Level Sensor: Service and Repair Fuel Tank and Filler Pipe - Exploded View
Fuel Tank and Filler Pipe - Exploded View
Explorer Sport Trac
NOTE: Vehicle body removed from art for clarity.
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel
Tank and Filler Pipe - Exploded View > Page 2414
Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel
Tank and Filler Pipe - Exploded View > Page 2416
1. For additional information, refer to the procedures.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel
Tank and Filler Pipe - Exploded View > Page 2417
Fuel Level Sensor: Service and Repair Fuel Level Sender
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 (FP). For additional information, refer to Fuel Pump See: Fuel Delivery
and Air Induction/Fuel Pump/Service and
Repair/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.
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.
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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 FP body.
2. Route the fuel level sender wire through the center of the FP.
3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate.
Hook the fuel level sender on the FP 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.
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6. Install the fuel level sender cover and screw and tighten the screw.
7. Install the FP. For additional information, refer to Fuel Pump See: Fuel Delivery and Air
Induction/Fuel Pump/Service and Repair/Fuel Pump.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Fuel Tank Pressure Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page
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Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page
2425
Fuel Tank Pressure Sensor: Description and Operation
Engine Control Components
Fuel Tank Pressure (FTP) Sensor
The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure.
Fuel Tank Pressure (FTP) Sensor
Fuel Tank Pressure (FTP) Sensor
In-line Fuel Tank Pressure (FTP) Sensor
In-line Fuel Tank Pressure (FTP) Sensor
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2426
Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor
Removal and Installation
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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: 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. For additional information, refer to
Evaporative Emission Canister See: Emission Control
Systems/Evaporative Emissions System/Evaporative Emission Control Canister/Service and
Repair.
2. Remove the fuel tank shield from the fuel tank.
3. Disconnect the Fuel Tank Pressure (FTP) sensor electrical connector.
4. Disconnect the 3 FTP sensor and vapor tube assembly quick connect couplings from the Fuel
Pump (FP) module and the vapor vent valves.
5. Remove the FTP sensor and vapor tube assembly.
6. To install, reverse the removal procedure.
- Carry out the Evaporative Emission System Leak Test. For additional information, refer to
Evaporative Emission System Leak Test See: Emission Control Systems/Evaporative Emissions
System/Testing and Inspection.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Intake Air Temperature Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
2430
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Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
2431
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
2432
Intake Air Temperature Sensor: Description and Operation
Engine Control Components
Intake Air Temperature (IAT) 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 sensor provides air temperature information to the PCM. The PCM uses the air
temperature information as a correction factor in the calculation of fuel, spark, and air flow.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Currently there are two 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 two 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.
Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors
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
Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into a Drop-in or Flange-type
MAF sensor
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
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Knock Sensor: Diagrams
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Knock Sensor: Description and Operation
Engine Control Components
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.
Two Types of Knock Sensor (KS)
Two Types of Knock Sensor (KS)
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Knock Sensor: Service and Repair
Knock Sensor (KS) - 4.0L SOHC
Removal and Installation
1. Remove the intake manifold.
2. Disconnect the Knock Sensor (KS) electrical connector.
3. Remove the bolt and the KS.
- To install, tighten to 20 Nm (177 lb-in).
4. To install, reverse the removal procedure.
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and Operation
Manifold Pressure/Vacuum Sensor: Description and Operation
Engine Control Components
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.
Typical Manifold Absolute Pressure (MAP) Sensor
Typical Manifold Absolute Pressure (MAP) Sensor
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Oil Temperature Sensor For ECM: Description and Operation
Engine Control Components
Engine Oil Temperature (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.
Typical Thread Type Sensor
Typical EOT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 2450
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 2451
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 2452
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 2453
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #21
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 2454
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 2455
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 2456
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 2457
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 2458
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22 > Page 2461
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22 > Page 2462
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22 > Page 2463
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation >
Heated Oxygen Sensor (HO2S)
Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S)
Engine Control Components
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.
Typical Heated Oxygen Sensor (HO2S)
Typical Heated Oxygen Sensor (HO2S)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation >
Heated Oxygen Sensor (HO2S) > Page 2466
Oxygen Sensor: Description and Operation Universal Heated Oxygen Sensor (HO2S)
Engine Control Components
Universal Heated Oxygen Sensor (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 HO2S 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor Exploded View
Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page 2469
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S)
Heated Oxygen Sensor (HO2S)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If the RH Heated Oxygen Sensor (HO2S) is being serviced, remove the 2 bolts and position the
heat shield aside.
3. Disconnect the HO2S electrical connector.
4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal.
Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S.
Installation
1. Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S.
2. Using the Exhaust Gas Oxygen Sensor Socket, install the HO2S.
- Calculate the correct torque wrench setting for the following torque.
- Using the Exhaust Gas Oxygen Sensor Socket, tighten to 41 Nm (30 lb-ft).
3. Connect the HO2S electrical connector.
4. If the RH HO2S is being serviced, position the heat shield and install the 2 bolts.
- Tighten to 20 Nm (177 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page 2470
Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
Catalyst Monitor Sensor
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If the RH Catalyst Monitor Sensor (CMS) is being serviced, remove the 2 bolts and position the
heat shield aside.
3. Disconnect the CMS electrical connector.
4. NOTE: If necessary, lubricate the CMS with penetrating and lock lubricant to ease removal.
Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS.
Installation
1. Apply a light coat of anti-seize lubricant to the threads of the CMS.
2. Using the Exhaust Gas Oxygen Sensor Socket, install the CMS.
- Calculate the correct torque wrench setting for the following torque.
- Using the Exhaust Gas Oxygen Sensor Socket, tighten to 41 Nm (30 lb-ft).
3. Connect the CMS electrical connector.
4. If the RH CMS is being serviced, position the heat shield and install the 2 bolts.
- Tighten to 20 Nm (177 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations >
Page 2474
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and
Operation > Power Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
Engine Control Components
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 EPC
pressure during increased engine load, for example during parking maneuvers.
Typical Power Steering Pressure (PSP) Switch
Typical Power Steering Pressure (PSP) Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and
Operation > Power Steering Pressure (PSP) Switch > Page 2477
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
Engine Control Components
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 EPC pressure during increased engine load, for example, during
parking maneuvers.
Typical Power Steering Pressure (PSP) Sensor
Typical Power Steering Pressure (PSP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Description and Operation
Pressure Feedback Exhaust Sensor: Description and Operation
Engine Control Components
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
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
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.
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View
Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System
Components - Exploded View
Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View > Page 2483
Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System
Module
Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC
Removal and Installation
1. Disconnect the EGR system module electrical and vacuum connectors.
2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting.
- To install, tighten to 40 Nm (30 lb-ft).
3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle
facing the intake manifold.
Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket.
- To install, tighten to 25 Nm (18 lb-ft).
4. NOTE: The EGR system module sealing surfaces are soft metals.
Carefully clean the EGR system module sealing surfaces.
5. To install, reverse the removal procedure.
- Install a new EGR system module gasket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC
P2135 Set
Throttle Position Sensor: Customer Interest A/C, Engine Controls - MIL ON/DTC P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC
P2135 Set > Page 2492
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL
ON/DTC P2135 Set
Throttle Position Sensor: All Technical Service Bulletins A/C, Engine Controls - MIL ON/DTC
P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL
ON/DTC P2135 Set > Page 2498
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 2499
Throttle Position Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 2500
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 2501
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Electronic Throttle Body (ETB) Throttle Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle
Position Sensor
Engine Control Components
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. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description
and Operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Electronic Throttle Body (ETB) Throttle Position Sensor > Page 2504
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
Engine Control Components
Throttle Position (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, four operating conditions are determined by the
PCM from the TP. These 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
Typical TP Sensor
Typical TP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Page 2505
Throttle Position Sensor: Service and Repair
Throttle Position (TP) Sensor
Removal
All vehicles
1. Remove the Air Cleaner (ACL) outlet pipe.
2. Disconnect the Throttle Position (TP) sensor electrical connector.
Vehicles equipped with a 4.6L (3V) engine
3. Disconnect the PCV hose from the heated PCV fitting.
4. Disconnect the heated PCV fitting electrical connector.
5. Remove the 2 bolts and the heated PCV fitting.
- Remove and discard the heated PCV fitting O-ring seal.
All vehicles
6. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts
because heat damage may occur. Damage
may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F).
NOTE: Do not use power tools.
Remove the TP sensor.
1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the
top TP sensor bolt ear reaches approximately
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Page 2506
55°C (130°F), this should take no more than 3 minutes using a 1100-watt heat gun. The heat gun
should be about an 25.4 mm (1 in) away from the ETB.
2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature
measuring device, such as a digital temperature
laser or infrared thermometer, while heating the ETB.
3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard.
4. Using hand tools, remove the remaining bolt and discard.
5. Remove and discard the TP sensor.
Installation
All vehicles
1. NOTE: Do not use power tools.
Install the new TP sensor.
- Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in).
Vehicles equipped with a 4.6L (3V) engine
2. Install a new O-ring seal and position the heated PCV fitting and install the 2 bolts.
3. Connect the heated PCV fitting electrical connector.
4. Connect the PCV hose to the heated PCV fitting.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Page 2507
All vehicles
5. Connect the TP sensor electrical connector.
6. Install the ACL outlet pipe.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations
Transmission Position Switch/Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2511
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2512
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2513
Transmission Position Switch/Sensor: Adjustments
5R55S
Transmission Range (TR) Sensor Adjustment
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 Transmission Range (TR) sensor connector.
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable end from the manual control lever.
6. Remove the manual control lever nut and the manual control lever.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2514
7. Loosen but do not remove the TR sensor screws.
8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence.
- Tighten to 8 Nm (71 lb-in).
9. Install the manual control lever and manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
11. Reconnect the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2515
12. Reinstall the rubber boot over the TR 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2516
Transmission Position Switch/Sensor: Service and Repair
5R55S
Digital Transmission Range (TR) Sensor
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
3. Move the TR sensor connector boot back to gain access to the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2517
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable from the manual control lever.
6. Remove the manual control lever nut.
7. Remove the TR sensor.
Installation
1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to
prevent damage to the sensor.
Install the TR sensor and loosely install the TR sensor screw and washer (2 required).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2518
2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual control lever must be in the NEUTRAL position.
Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence. Tighten to 8 Nm (71 lb-in).
3. Install the manual control lever and the manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
5. Connect the TR sensor connector.
6. Move the TR sensor connector boot back over the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2519
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Output Shaft Speed (OSS) Sensor
Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor
Engine Control Components
Output Shaft Speed (OSS) Sensor
The OSS sensor provides the PCM with information about the rotational speed of an output shaft.
The PCM uses the information to control and diagnose powertrain behavior. In some applications,
the sensor is also used as the source of vehicle speed. The sensor may be physically located in
different places on the vehicle, depending upon the specific application. The design of each speed
sensor is unique and depends on which powertrain control feature uses the information that is
generated.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Output Shaft Speed (OSS) Sensor > Page 2524
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS)
Engine Control Components
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 speed, 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.
Typical Vehicle Speed Sensor (VSS)
Typical Vehicle Speed Sensor (VSS)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
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
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
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.
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and
Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View
Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System
Components - Exploded View
Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and
Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View > Page 2531
Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System
Module
Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC
Removal and Installation
1. Disconnect the EGR system module electrical and vacuum connectors.
2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting.
- To install, tighten to 40 Nm (30 lb-ft).
3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle
facing the intake manifold.
Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket.
- To install, tighten to 25 Nm (18 lb-ft).
4. NOTE: The EGR system module sealing surfaces are soft metals.
Carefully clean the EGR system module sealing surfaces.
5. To install, reverse the removal procedure.
- Install a new EGR system module gasket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 2536
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 2537
Accelerator Pedal Position Sensor: Description and Operation
Engine Control Components
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
There are two 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 two
pedal position signals make sure the PCM receives a correct input even if one 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 two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six
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 (TP) 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. For additional information, refer
to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic
Throttle Control Module/Description and Operation.
2-Track APP Sensor
Typical 2-Track APP Sensor
3-Track APP Sensor
There are three 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 three pedal position signals make sure the PCM
receives a correct input even if one 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 two reference voltage circuits, two signal
return circuits, and three signal circuits (a total of seven 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. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description
and Operation.
3-Track APP Sensor
Typical 3-Track APP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2541
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2542
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2543
Air Flow Meter/Sensor: Description and Operation
Engine Control Components
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 (TCC) 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 IAT sensor.
The hot wire electronic sensing element must be replaced as an assembly. Replacing only the
element may change the air flow calibration.
Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT
Sensor Wire Where Applicable) Terminals
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
Typical Mass Air Flow (MAF) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2544
Typical Drop-in Mass Air Flow (MAF) Sensor
Typical Drop-in Mass Air Flow (MAF) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2545
Air Flow Meter/Sensor: Service and Repair
Mass Air Flow (MAF) Sensor - 4.0L SOHC
Removal and Installation
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the 2 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations
Fuel Pressure Sensor/Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page
2549
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page
2550
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page
2551
Fuel Pressure Sensor/Switch: Description and Operation
Engine Control Components
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.
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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2552
Fuel Pressure Sensor/Switch: Service and Repair
Fuel Rail Pressure and Temperature Sensor - 4.0L SOHC
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.
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.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Remove the intake manifold.
4. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
5. Remove the 2 bolts and the fuel rail pressure and temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. Remove and discard the O-ring seal.
7. NOTICE: Use an O-ring seal made of special fuel resistant material. Fuel will damage ordinary
O-ring seals and may cause the fuel
system to leak.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page
2553
NOTICE: Do not reuse the O-ring seal. The removal and installation process may damage the used
O-ring seals and cause the fuel system to leak.
To install, reverse the removal procedure.
- Lubricate the new O-ring seal with clean engine oil.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations
Fuel Temperature Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 2557
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 2558
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 2559
Fuel Temperature Sensor: Description and Operation
Engine Control Components
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.
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 2560
Fuel Temperature Sensor: Service and Repair
Fuel Rail Pressure and Temperature Sensor - 4.0L SOHC
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.
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.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Remove the intake manifold.
4. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
5. Remove the 2 bolts and the fuel rail pressure and temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. Remove and discard the O-ring seal.
7. NOTICE: Use an O-ring seal made of special fuel resistant material. Fuel will damage ordinary
O-ring seals and may cause the fuel
system to leak.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 2561
NOTICE: Do not reuse the O-ring seal. The removal and installation process may damage the used
O-ring seals and cause the fuel system to leak.
To install, reverse the removal procedure.
- Lubricate the new O-ring seal with clean engine oil.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 2565
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 2566
Inertia Fuel Shutoff Switch: Description and Operation
Engine Control Components
Inertia Fuel Shut-off (IFS) Switch
The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is
to shut off the fuel pump if a collision occurs. It consists of a steel cone held in place by a magnet.
When a sharp impact occurs, the cone 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.
Typical Inertia Fuel Shut-off (IFS) Switch
Typical Inertia Fuel Shut-off (IFS) Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 2567
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.
NOTE: 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 2 bolts and the IFS switch.
- To install, tighten to 2 Nm (18 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC
P2135 Set
Throttle Position Sensor: Customer Interest A/C, Engine Controls - MIL ON/DTC P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC
P2135 Set > Page 2576
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL
ON/DTC P2135 Set
Throttle Position Sensor: All Technical Service Bulletins A/C, Engine Controls - MIL ON/DTC
P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL
ON/DTC P2135 Set > Page 2582
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 2583
Throttle Position Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 2584
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 2585
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Electronic Throttle Body (ETB) Throttle Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle
Position Sensor
Engine Control Components
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. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description
and Operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Electronic Throttle Body (ETB) Throttle Position Sensor > Page 2588
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
Engine Control Components
Throttle Position (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, four operating conditions are determined by the
PCM from the TP. These 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
Typical TP Sensor
Typical TP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Page 2589
Throttle Position Sensor: Service and Repair
Throttle Position (TP) Sensor
Removal
All vehicles
1. Remove the Air Cleaner (ACL) outlet pipe.
2. Disconnect the Throttle Position (TP) sensor electrical connector.
Vehicles equipped with a 4.6L (3V) engine
3. Disconnect the PCV hose from the heated PCV fitting.
4. Disconnect the heated PCV fitting electrical connector.
5. Remove the 2 bolts and the heated PCV fitting.
- Remove and discard the heated PCV fitting O-ring seal.
All vehicles
6. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts
because heat damage may occur. Damage
may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F).
NOTE: Do not use power tools.
Remove the TP sensor.
1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the
top TP sensor bolt ear reaches approximately
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Page 2590
55°C (130°F), this should take no more than 3 minutes using a 1100-watt heat gun. The heat gun
should be about an 25.4 mm (1 in) away from the ETB.
2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature
measuring device, such as a digital temperature
laser or infrared thermometer, while heating the ETB.
3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard.
4. Using hand tools, remove the remaining bolt and discard.
5. Remove and discard the TP sensor.
Installation
All vehicles
1. NOTE: Do not use power tools.
Install the new TP sensor.
- Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in).
Vehicles equipped with a 4.6L (3V) engine
2. Install a new O-ring seal and position the heated PCV fitting and install the 2 bolts.
3. Connect the heated PCV fitting electrical connector.
4. Connect the PCV hose to the heated PCV fitting.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Page 2591
All vehicles
5. Connect the TP sensor electrical connector.
6. Install the ACL outlet pipe.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor
1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor
1 > Page 2597
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor
1 > Page 2598
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
> Page 2601
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
> Page 2602
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2603
Camshaft Position Sensor: Description and Operation
Engine Control Components
Camshaft Position (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 two CMP sensors are equipped with variable camshaft timing (VCT). The second
sensor is used to identify the position of the camshaft on bank 2.
There are two types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin
Hall-effect type sensor.
Typical Variable Reluctance CMP Sensor
Typical Variable Reluctance CMP Sensor
Typical Hall-effect CMP Sensor
Typical Hall-effect CMP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2604
Camshaft Position Sensor: Service and Repair
Camshaft Position (CMP) Sensor - 4.0L SOHC
Removal and Installation
1. Disconnect the Camshaft Position (CMP) sensor electrical connector.
2. Remove the bolt and the CMP sensor.
- To install, tighten to 6 Nm (53 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2608
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2609
Crankshaft Position Sensor: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2610
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2611
Crankshaft Position Sensor: Description and Operation
Engine Control Components
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.
Typical Crankshaft Position (CKP) Sensor
Typical Crankshaft Position (CKP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2612
Crankshaft Position Sensor: Service and Repair
Crankshaft Position (CKP) Sensor - 4.0L SOHC
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
3. Remove the 2 bolts and the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. NOTE: Be sure the sensor wiring is routed away from the battery cable.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Ignition Lock Cylinder - Functional
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.
NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a
new lock cylinder using the appropriate lock repair package. The lock repair package includes a
detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. With the ignition switch in the RUN position, press the locking pin with a suitable tool and remove
the ignition lock cylinder.
2. If a new lock cylinder with keys is replaced, the new Passive Anti-Theft System (PATS) keys
must be programmed.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional > Page 2618
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Ignition Lock Cylinder - Non Functional
Removal
1. Remove the Passive Anti-Theft System (PATS) transceiver.
2. Remove the ignition lock cylinder.
- Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
- Use a 3/8-inch diameter drill bit to drill down the middle of the ignition lock key slot until the
ignition lock cylinder breaks loose.
- Remove and discard the ignition lock cylinder and drill shavings from the steering column.
3. Remove the bearing retainer.
4. Remove the steering column lock housing bearing and steering column lock gear.
Installation
1. Thoroughly clean all drill shavings from the steering column and inspect it for damage.
2. Install a new ignition lock cylinder.
- Verify the ignition lock cylinder operation.
3. Program the new PATS keys.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2622
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2623
Knock Sensor: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2624
Knock Sensor: Description and Operation
Engine Control Components
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.
Two Types of Knock Sensor (KS)
Two Types of Knock Sensor (KS)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2625
Knock Sensor: Service and Repair
Knock Sensor (KS) - 4.0L SOHC
Removal and Installation
1. Remove the intake manifold.
2. Disconnect the Knock Sensor (KS) electrical connector.
3. Remove the bolt and the KS.
- To install, tighten to 20 Nm (177 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications
Fuel Pressure: Specifications
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications > Page 2630
Fuel Pressure: Testing and Inspection
Fuel System Pressure Test
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.
WARNING: 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.
WARNING: 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. Release the fuel system pressure. For additional information, refer to Fuel System Pressure
Release See: Fuel Filter/Fuel Pressure Release/Service
and Repair.
2. Disconnect the battery ground cable.
3. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. For additional information, refer
to Spring Lock Couplings See: Fuel Delivery
and Air Induction/Fuel Line Coupler/Service and Repair/Spring Lock Couplings.
4. NOTE: 4.6L shown, 4.0L similar.
Install the Fuel Pressure Test Kit in line between the fuel supply tube and fuel rail.
5. NOTE: The Inertia Fuel Shutoff (IFS) switch electrical connector was disconnected during fuel
system pressure release.
Connect the IFS switch electrical connector.
6. Connect the battery ground cable.
7. 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.
8. Test the fuel system pressure to make sure it is within the specified range. For additional
information, refer to Specifications.
9. NOTE: 4.6L shown, 4.0L similar.
NOTE: 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 Fuel Pressure Test
Kit and relieve the fuel system pressure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications > Page 2631
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 Hot Idle ............................................................................................................
.......................................................................................... 750 - 820 RPM
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Service and Repair > Intake Air System Components - Exploded View
Air Filter Element: Service and Repair Intake Air System Components - Exploded View
Intake Air System Components - Exploded View
Coolant Expansion Tank
Intake Air System Components (4.0L SOHC)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page
2640
Intake Air System Components - 4.6L (3V)
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page
2641
Air Filter Element: Service and Repair Air Cleaner Element
Air Cleaner Element
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 element.
6. NOTE: Clean the inside of the ACL tray.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
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. 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.
NOTE: It may be necessary to reposition the lower end of the door jam weatherstripping to remove
the front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the Inertia Fuel Shutoff (IFS) switch electrical connector.
4. Start the engine and allow it to idle until it stalls.
5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail
pressure has been released.
6. Turn the ignition switch to the OFF position.
7. When the fuel system service is complete, reconnect the IFS switch electrical connector.
8. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before
starting the engine.
9. Start the vehicle and check the fuel system for leaks.
10. Install the front passenger side interior kick panel.
11. Install the front passenger door frame scuff plate.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications
Firing Order: Specifications
Firing order...........................................................................................................................................
..................................................................1-4-2-5-3-6
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > System
Information > Specifications
Ignition Timing: Specifications
Base ignition timing................................................................................................................10
degrees Before Top Dead Center (BTDC), Non-adjustable
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service and Repair
Ignition Cable: Service and Repair
Spark Plug Wires
Removal and Installation
1. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible
damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. For additional
information, refer to the Cylinder-to-Coil Terminal Relationship, Engine Ignition See: Ignition
System/Description and Operation in the Description and Operation.
Squeeze the locking tabs and twist while pulling upward to disconnect the 6 spark plug wires from
the ignition coil.
2. Detach the spark plug wires from the spark plug wire retainers.
3. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible
damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct spark plug.
With a twisting motion, use the Spark Plug Wire Remover to pull the spark plug wires from the
spark plugs.
4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Gap
Spark Plug: Specifications Gap
Item.......................................................................................................................................................
...............................................................Specification
Spark Plug Gap....................................................................................................................................
....................................1.32-1.42 mm (0.052-0.056 in)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Gap > Page 2659
Spark Plug: Specifications Torque Specifications
Spark plugs...........................................................................................................................................
........................................................17 Nm (150 lb-in)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2660
Spark Plug: Application and ID
Item.......................................................................................................................................................
...............................................................Specification
Spark Plug type....................................................................................................................................
....................................................................AGSF24N
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2661
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.
- Install a new 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.
5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine
damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized
installation of a heli-coil insert in place of the spark plug threads. Install a new spark plug.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2662
6. Inspect for overheating, identified by white or light gray spots and 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Service and Repair > Engine Ignition Components - Exploded View
Spark Plug: Service and Repair Engine Ignition Components - Exploded View
Engine Ignition Components - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Service and Repair > Engine Ignition Components - Exploded View > Page 2665
Spark Plug: Service and Repair Spark Plugs
Spark Plugs
Removal and Installation
1. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible
damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct spark plug. Refer to the Cylinder-to-Coil
Terminal Relationship, Engine Ignition See: Ignition System/Description and Operation in the
Description and Operation.
With a twisting motion, use the Spark Plug Wire Remover to pull the spark plug wire from the spark
plug.
2. NOTE: Use compressed air to remove any foreign material from the spark plug wells before
removing the spark plugs.
Remove the spark plugs.
- To install, tighten to 17 Nm (150 lb-in).
3. Use a suitable spark plug gap tool to check and adjust the spark plug gap.
4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications
Compression Check: Specifications
Compression Test - Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart.
Compression Pressure Limit Chart
If one or more cylinders reads 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 within 75% of the highest reading.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 2669
Compression Check: Testing and Inspection
Engine
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 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
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the
pistons in the low-reading cylinders. Repeat the
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 2670
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 within 75% of the highest reading.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor
> Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor
> Component Information > Locations > Page 2675
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor
> Component Information > Locations > Page 2676
Accelerator Pedal Position Sensor: Description and Operation
Engine Control Components
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
There are two 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 two
pedal position signals make sure the PCM receives a correct input even if one 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 two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six
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 (TP) 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. For additional information, refer
to Torque Based Electronic Throttle Control (ETC) See: Electronic Throttle Control
Module/Description and Operation.
2-Track APP Sensor
Typical 2-Track APP Sensor
3-Track APP Sensor
There are three 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 three pedal position signals make sure the PCM
receives a correct input even if one 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 two reference voltage circuits, two signal
return circuits, and three signal circuits (a total of seven 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. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) See: Electronic Throttle Control Module/Description and Operation.
3-Track APP Sensor
Typical 3-Track APP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations
Air Flow Meter/Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 2680
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 2681
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 2682
Air Flow Meter/Sensor: Description and Operation
Engine Control Components
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 (TCC) 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 IAT sensor.
The hot wire electronic sensing element must be replaced as an assembly. Replacing only the
element may change the air flow calibration.
Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT
Sensor Wire Where Applicable) Terminals
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
Typical Mass Air Flow (MAF) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 2683
Typical Drop-in Mass Air Flow (MAF) Sensor
Typical Drop-in Mass Air Flow (MAF) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 2684
Air Flow Meter/Sensor: Service and Repair
Mass Air Flow (MAF) Sensor - 4.0L SOHC
Removal and Installation
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the 2 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations
Intake Air Temperature Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 2688
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 2689
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 2690
Intake Air Temperature Sensor: Description and Operation
Engine Control Components
Intake Air Temperature (IAT) 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 sensor provides air temperature information to the PCM. The PCM uses the air
temperature information as a correction factor in the calculation of fuel, spark, and air flow.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Currently there are two 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 two 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.
Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors
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
Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into a Drop-in or Flange-type
MAF sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Locations
Brake Signal: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Locations > Page 2694
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Locations > Page 2695
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Description and Operation > Brake Pedal Position (BPP) Switch
Brake Signal: Description and Operation Brake Pedal Position (BPP) Switch
Engine Control Components
Brake Pedal Position (BPP) Switch
The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal
to the PCM indicating the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Typical BPP Switch
Typical BPP Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 2698
Brake Signal: Description and Operation Brake Pedal Switch (BPS)/Brake Deactivator Switch
Engine Control Components
Brake Pedal Switch (BPS)/Brake Deactivator Switch
The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A
normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is
not applied. When the brake pedal is applied, the normally closed switch opens and power is
removed from the PCM.
On some applications the normally closed BPS, along with the normally open BPP switch, are used
for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be
disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not
changing states when they were expected to, a diagnostic trouble code (DTC) is set by the PCM
strategy.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Camshaft Position Sensor 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Camshaft Position Sensor 1 > Page 2703
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Camshaft Position Sensor 1 > Page 2704
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Camshaft Position Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Camshaft Position Sensor > Page 2707
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Camshaft Position Sensor > Page 2708
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Page 2709
Camshaft Position Sensor: Description and Operation
Engine Control Components
Camshaft Position (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 two CMP sensors are equipped with variable camshaft timing (VCT). The second
sensor is used to identify the position of the camshaft on bank 2.
There are two types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin
Hall-effect type sensor.
Typical Variable Reluctance CMP Sensor
Typical Variable Reluctance CMP Sensor
Typical Hall-effect CMP Sensor
Typical Hall-effect CMP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Page 2710
Camshaft Position Sensor: Service and Repair
Camshaft Position (CMP) Sensor - 4.0L SOHC
Removal and Installation
1. Disconnect the Camshaft Position (CMP) sensor electrical connector.
2. Remove the bolt and the CMP sensor.
- To install, tighten to 6 Nm (53 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component
Information > Description and Operation
Clutch Switch: Description and Operation
Engine Control Components
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.
Typical Clutch Pedal Position (CPP) Switch
Typical Clutch Pedal Position (CPP) Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Page 2717
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Page 2718
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Engine Control Components
Engine Coolant Temperature (ECT) Sensor
The ECT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases, and the resistance
increases as the temperature decreases. The varying resistance changes the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor
determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage
minus the voltage drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The PCM uses the ECT input for fuel
control and for cooling fan control. There are three types of ECT sensors, threaded, push-in, and
twist-lock. The ECT sensor is located in an engine coolant passage.
Typical Thread Type Sensor
Typical Thread Type ECT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Page 2719
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature (ECT) Sensor - 4.0L SOHC
Removal and Installation
1. Drain the cooling system.
2. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
3. Remove the clip and the ECT sensor.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations
Crankshaft Position Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 2723
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 2724
Crankshaft Position Sensor: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 2725
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 2726
Crankshaft Position Sensor: Description and Operation
Engine Control Components
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.
Typical Crankshaft Position (CKP) Sensor
Typical Crankshaft Position (CKP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 2727
Crankshaft Position Sensor: Service and Repair
Crankshaft Position (CKP) Sensor - 4.0L SOHC
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
3. Remove the 2 bolts and the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. NOTE: Be sure the sensor wiring is routed away from the battery cable.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations > Page 2731
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Locations
Electronic Throttle Actuator: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Locations > Page 2735
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Locations > Page 2736
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Locations > Page 2737
Electronic Throttle Actuator: Description and Operation
Engine Control Components
Electronic Throttle Actuator Control (TAC)
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.
This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine
airflow required at idle. For additional information, refer to Torque Based Electronic Throttle Control
(ETC) See: Electronic Throttle Control Module/Description and Operation.
Typical In-line TAC Design
Typical In-line TAC Design
Typical Parallel TAC Design
Typical Parallel TAC Design
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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), which delivers 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 torque-based 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 two 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. 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 one reference voltage and one signal return circuit between the PCM and the ETB. The
reference voltage and the signal return circuits are shared with the reference voltage and signal
return circuits used by the accelerator pedal position (APP) sensor. There are also two throttle
position (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. For additional
information on the APP sensor, refer to Engine Control Components See: Description and
Operation/Engine Control Components.
Electronic Throttle Control (ETC) System Strategy
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)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 2741
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 two 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.
ETC System With A 3-Track APP Sensor Failure Mode And Effects Management:
a - ETC illuminates or displays a message on the message center immediately; MIL illuminates
after 2 driving cycles
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 2742
ETC System With A 2-Track APP Sensor Failure Mode And Effects Management:
Electronic Throttle Monitor Operation:
a - Monitor execution is continuous. Monitor false detection duration is less than 1 second to
register a concern.
APP and TP Sensor Inputs
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 2743
Accelerator Pedal Position (APP) Sensor Check:
Correlation and range/performance - sensor disagreement between processors internal to the
PCM. Monitor execution is continuous. Monitor false detection duration is less than 1 second to
register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions for additional
DTC information.
Throttle Position (TP) Sensor Check:
a - Correlation and range/performance - sensor disagreement between processors internal to the
PCM, TP inconsistent with requested throttle plate position. Monitor execution is continuous.
Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic
Trouble Code (DTC) Charts and Descriptions for additional DTC information.
Electronic Throttle Actuator Control (TAC) Output
Electronic TAC Operation Check:
a - Note: For all DTCs, in addition to the MIL, the powertrain malfunction indicator (wrench) is on for
the concern that caused the FMEM action. Monitor execution is continuous. Monitor false detection
duration is less than 5 seconds to register a concern.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift
Engine Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift > Page 2752
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift > Page 2753
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-18-10 > Sep > 09 > Engine,
A/T Controls - Driveline Bump/Harsh 1-2 Shift
Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-18-10 > Sep > 09 > Engine,
A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 2759
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-18-10 > Sep > 09 > Engine,
A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 2760
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-22-15 >
Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's
Evaporator Drain Tube: All Technical Service Bulletins A/T Controls - MIL ON/Various A/T Solenoid
DTC's
TSB 09-22-15
11/16/09
5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION
FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR
BEFORE 8/12/2009
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or
before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with
diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related
DTCs. This may be due to water traveling down from the A/C drain into the solenoid body
connector on the left side of the transmission.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify any transmission related symptoms or transmission related DTC's that are present.
2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be
coming from the A/C drain. (Figure 1)
3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed.
4. Cut and install patch kit over the connector. (Figure 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-22-15 >
Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's > Page 2766
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092215A 2006-2010 Explorer, 0.4 Hr.
Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease
Connector, Install Patch (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7G391 X2
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-22-15 >
Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's > Page 2772
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092215A 2006-2010 Explorer, 0.4 Hr.
Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease
Connector, Install Patch (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7G391 X2
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 2773
Engine Control Module: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 2774
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 2775
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 2776
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 2777
Engine Control Module: Diagrams
C175B Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 2778
C175B Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 2779
C175E Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 2780
C175E Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 2781
C175E Part 3
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 2782
C175T Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 2783
C175T Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 DTC P1635 or
P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware
or parameter changes made to the vehicle since production. Failure to carry out this procedure
properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle
ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID
Block and also under Making Changes to the PCM Calibration. The VID block contains many items
used by the strategy for a variety of functions. Some of these items include the vehicle identification
number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the
presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual
shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID
block is displayed on the scan tool.
When changing items in the VID block, the strategy places range limits on certain items such as
tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this
limit is reached, the scan tool displays a message indicating the need to flash the PCM again to
reset the VID block.
On selected vehicles equipped with permanent DTC reporting capabilities, neutral profile correction
should be learned after a PCM replacement in order to activate the misfire monitor. This can be
accomplished using the Misfire Monitor Neutral Profile Learn function on the scan tool.
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.
Neutral Profile Correction
In order for the misfire detection system to function properly, any mechanical inaccuracies in the
crankshaft position (CKP) sensor must be learned by the PCM. This information is stored in
non-volatile memory (NVM) in the PCM. It is not cleared when the keep alive memory (KAM) is
reset.
Neutral profile learning is accomplished using the scan tool any time a PCM is replaced. It should
also be relearned any time the CKP sensor is replaced or major engine repairs have been
completed.
To determine if the neutral profile learning has been completed, check the MP_LRN parameter
identification (PID) using the scan tool. The PID should read YES if the neutral profile learning has
been completed. If the PID reads NO, complete the neutral profile learning prior to diagnosing any
misfire DTCs.
Programming the VID Block for a Replacement PCM
The VID block on a replacement PCM is blank and requires programming. There are two
procedures available. The first is an automatic data transfer from the old PCM to the new PCM,
and the second is manual data entry into the new PCM.
Automatic data transfer 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 be downloaded to the new PCM after it has been installed.
Carry out manual data entry if the old PCM 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 programmed PCM 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Service and Repair > Procedures > Page 2786
At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production, or the need to reset the VID block
because it has reached its limit. Refer to Module Reprogramming on the scan tool.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Service and Repair > Procedures > Page 2787
Engine Control Module: Removal and Replacement
Powertrain Control Module (PCM)
A/C Tube Brackets
PCM
Removal
All vehicles
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Service and Repair > Procedures > Page 2788
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 (PMI) procedure. See: Information Bus/Testing and
Inspection/Programming and Relearning
Vehicles equipped with a 4.6L (3V) engine
2. Remove the Air Cleaner (ACL).
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 2 bolts and the PCM.
Installation
All vehicles
1. Install the PCM and the 2 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.
- Tighten to 7 Nm (62 lb-in).
Vehicles equipped with a 4.6L (3V) engine
4. Install the ACL.
All vehicles
5. Restore the module configuration. Carry out the module configuration restore steps of the
Programmable Module Installation (PMI) procedure.
See: Information Bus/Testing and Inspection/Programming and Relearning
6. Reprogram the Passive Anti-Theft System (PATS). Carry out the Parameter Reset procedure.
See: Accessories and Optional Equipment/Antitheft
and Alarm Systems/Testing and Inspection/Programming and Relearning/Passive Anti-Theft
System (PATS) Parameter Reset
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Locations > Page 2792
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Locations > Page 2793
Engine Temperature Sensor: Description and Operation
Engine Control Components
Cylinder Head Temperature (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. For
additional information, refer to Powertrain Control Software See: Description and
Operation/Powertrain Control Software for Fail-Safe Cooling Strategy.
Typical CHT Sensor
Typical CHT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Description and Operation
Fuel Level Sensor: Description and Operation
Engine Control Components
Fuel Level Input (FLI)
The FLI is a communications network message. Most vehicle applications use a potentiometer type
FLI sensor connected to a float in the FP module to determine fuel level.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View
Fuel Level Sensor: Service and Repair Fuel Tank and Filler Pipe - Exploded View
Fuel Tank and Filler Pipe - Exploded View
Explorer Sport Trac
NOTE: Vehicle body removed from art for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2799
Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2800
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2801
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2802
Fuel Level Sensor: Service and Repair Fuel Level Sender
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 (FP). For additional information, refer to Fuel Pump See: Fuel Delivery
and Air Induction/Fuel Pump/Service and
Repair/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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2803
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 FP body.
2. Route the fuel level sender wire through the center of the FP.
3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate.
Hook the fuel level sender on the FP 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2804
6. Install the fuel level sender cover and screw and tighten the screw.
7. Install the FP. For additional information, refer to Fuel Pump See: Fuel Delivery and Air
Induction/Fuel Pump/Service and Repair/Fuel Pump.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Locations
Fuel Tank Pressure Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Locations > Page 2808
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Locations > Page 2809
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Locations > Page 2810
Fuel Tank Pressure Sensor: Description and Operation
Engine Control Components
Fuel Tank Pressure (FTP) Sensor
The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure.
Fuel Tank Pressure (FTP) Sensor
Fuel Tank Pressure (FTP) Sensor
In-line Fuel Tank Pressure (FTP) Sensor
In-line Fuel Tank Pressure (FTP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Locations > Page 2811
Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor
Removal and Installation
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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: 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. For additional information, refer to
Evaporative Emission Canister See: Emission Control
Systems/Evaporative Emissions System/Evaporative Emission Control Canister/Service and
Repair.
2. Remove the fuel tank shield from the fuel tank.
3. Disconnect the Fuel Tank Pressure (FTP) sensor electrical connector.
4. Disconnect the 3 FTP sensor and vapor tube assembly quick connect couplings from the Fuel
Pump (FP) module and the vapor vent valves.
5. Remove the FTP sensor and vapor tube assembly.
6. To install, reverse the removal procedure.
- Carry out the Evaporative Emission System Leak Test. For additional information, refer to
Evaporative Emission System Leak Test See: Emission Control Systems/Evaporative Emissions
System/Testing and Inspection.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
Idle Air Control (IAC) Valve
Note: The IAC valve assembly is not adjustable and cannot be cleaned, also some IAC valves are
normally open and others are normally closed. Some IAC valves require engine vacuum to
operate.
The IAC valve assembly controls the engine idle speed and provides a dashpot function. The IAC
valve assembly meters intake air around the throttle plate through a bypass within the IAC valve
assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals
the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the
IAC valve to control the amount of bypassed air. The PCM monitors engine RPM and increases or
decreases the IAC duty cycle in order to achieve the desired RPM.
The PCM uses the IAC valve assembly to control:
- no touch start
- cold engine fast idle for rapid warm-up
- idle (corrects for engine load)
- stumble or stalling on deceleration (provides a dashpot function)
- over-temperature idle boost
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions
Information Bus: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2819
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2820
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2821
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2822
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
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2823
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery 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 loose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2824
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2825
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2826
Symbols (Part 4)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2827
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2828
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.
Defective insulation stripping
1 = Proper crimp
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2829
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2830
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2831
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2832
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2833
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.
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.
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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 Speed (MS) and High Speed (HS) 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 Controller Area Network (MS-CAN)
- High Speed Controller Area Network (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 Control Module (ACM).
Network Topology
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Medium Speed Controller Area Network (MS-CAN) 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:
- Accessory Protocol Interface Module (APIM)
- Audio Control Module (ACM)
- Driver Seat Module (DSM) (if equipped)
- HVAC module (if equipped)
- Instrument Cluster (IC)
- Parking Aid Module (PAM) (if equipped)
- Power Running Board (PRB) module (if equipped)
- Rear Entertainment Module (RETM) (if equipped)
- Satellite Digital Audio Receiver System (SDARS) module (if equipped)
- Smart Junction Box (SJB)
High Speed Controller Area Network (HS-CAN) 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:
- 4X4 control module (if equipped)
- ABS module
- APIM
- IC
- Occupant Classification System Module (OCSM)
- PCM
- Restraints Control Module (RCM)
- Transmission Control Module (TCM) (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
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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 IC 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 IC is the only module on this
vehicle that has this ability.
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Information Bus: Initial Inspection and Diagnostic Overview
Special Tools Used With Diagnostics
Communications Network
Principles Of Operation
Communications Network
Principles of Operation
NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM).
Vehicle communication utilizes both Medium Speed (MS) and High Speed (HS) 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 Controller Area Network (MS-CAN)
- High Speed Controller Area Network (HS-CAN)
Medium Speed Controller Area Network (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:
- Accessory Protocol Interface Module (APIM) (if equipped)
- Audio Control Module (ACM)
- Driver Seat Module (DSM) (if equipped)
- HVAC module (if equipped)
- Instrument Cluster (IC)
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- Parking Aid Module (PAM) (if equipped)
- Power Running Board (PRB) module (if equipped)
- Rear Entertainment Module (RETM) (if equipped)
- Satellite Digital Audio Receiver System (SDARS) module (if equipped)
- Smart Junction Box (SJB)
The following fault chart describes the specific MS-CAN failures and their resulting symptom:
Medium Speed Controller Area Network (MS-CAN) Communication Fault Chart
High Speed Controller Area Network (HS-CAN)
The HS-CAN is a high speed communication network that uses an unshielded twisted pair cable of
data (+) and data (-) circuits. The data (+) and the data (-) circuits are each regulated to
approximately 2.5 volts during neutral or rested network traffic. As bus messages are sent on the
data (+) circuit, voltage is increased by approximately 1.0 volt. Inversely, the data (-) circuit is
reduced by approximately 1.0 volt when a bus message is sent. Multiple bus messages can be
sent over the network CAN circuits allowing multiple modules to communicate with each other. The
HS-CAN 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:
- 4X4 control module (if equipped)
- ABS module
- Accessory Protocol Interface Module (APIM) (if equipped)
- Instrument Cluster (IC)
- Occupant Classification System Module (OCSM)
- PCM
- Restraints Control Module (RCM)
- Transmission Control Module (TCM) (if equipped)
The following fault chart describes the specific HS-CAN failures and their resulting symptom:
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High Speed Controller Area Network (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 Commnication Message Chart (Part 1)
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CAN Module Commnication Message Chart (Part 2)
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CAN Module Commnication Message Chart (Part 3)
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CAN Module Commnication Message Chart (Part 4)
CAN Module Commnication Message Chart (Part 5)
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Inspection And Verification
Communications Network
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of electrical damage.
- If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
Visual Inspection Chart
3. Connect the scan tool to the DLC.
- NOTE: Make sure to use the latest scan tool software release.
NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground
from the DLC are provided to the VCM.
If the Integrated Diagnostic System (IDS) 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 U, to diagnose No Power To The Scan Tool. See: Pinpoint Tests/Pinpoint
Test U: No Power To The Scan Tool
4. Establish a scan tool session.
- NOTE: 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.
If an IDS session cannot be established with the vehicle, (IDS may state "No communication can
be established with the PCM"): Choose "NO" when the scan tool prompts whether or not to retry communication.
- Enter either a PCM part number, tear tag or calibration number to identify the vehicle and start a
session (the PCM part number and
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4-character tear tag are printed on the PCM label).
- Go To Pinpoint Test A, to diagnose "The PCM Does Not Respond To The Scan Tool". See:
Pinpoint Tests/Pinpoint Test A: The PCM Does Not Respond To The Scan Tool
5. 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 diagnose the failed communication network.
See: Symptom Related Diagnostic Procedures
- If a module fails to communicate during the network test, GO to Symptom Chart. See: Symptom
Related Diagnostic Procedures
6. Retrieve and review the DTCs.
- If the DTCs retrieved are related to the concern, go to DTC Charts. Follow the non-network DTC
diagnostics (B-codes, C-codes, P-codes) prior to the network DTC diagnostics (U-codes). For all
other DTCs, refer to the Diagnostic Trouble Code (DTC) Chart in Body Control Systems. See:
Diagnostic Trouble Code Descriptions/Communications Network See: Body and Frame/Body
Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble
Code (DTC) Chart
- If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures
Special Tools Used With Diagnostics
Module Configuration
Principles Of Operation
Module Configuration
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 incorrect
operation and/or DTCs setting.
The following are the 3 different methods of configuration:
- Programmable Module Installation (PMI)
- Module reprogramming ("flashing")
- Programmable parameters
Some modules do not support all 3 methods.
Definition of Terms
The following are definitions of configuration terms:
Programmable Module Installation (PMI)
PMI is a scan tool process which configures settings in a new module. Data used for the PMI
process is automatically downloaded from the original module and stored when a scan tool session
is started. If this data cannot be retrieved from the module being replaced, the scan tool may
prompt for As-Built data entry or display a list of parameter values that need to be manually
selected. Some modules are reprogrammed during PMI when a strategy/calibration update is
available. To carry out PMI, refer to Programmable Module Installation (PMI) See: Programming
and Relearning.
NOTE: It is important that the scan tool identifies the vehicle and obtains configuration data prior to
removing any modules. The new module must be
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able to communicate with the scan tool in order to carry out PMI. 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. Reprogramming a module with the same level of software will not
improve module operation or repair a hardware failure. Module reprogramming is automatically
carried out during PMI when a later strategy/calibration is available.
NOTE: Module reprogramming should be limited to circumstances where a published TSB
procedure recommends doing so.
NOTE: 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 the reprogramming process.
Accessory Protocol Interface Module (APIM) Programming
APIM programming is a process that updates the APIM Consumer Interface Processor (CIP) and
Vehicle Interface Processor (VIP) software. The VIP programming updates the calibration files in
the portion of the APIM that interfaces with the Controller Area Network (CAN). The CIP
programming updates calibration files in the portion of the APIM that interfaces with mobile phones
and other customer devices.
APIM programming uses the VCM to read and program the VIP software through the Data Link
Connector (DLC). A web-based OASIS application is used to read and program the CIP software
via a Universal Serial Bus (USB) cable between the scan tool and vehicle USB port. Both the VCM
and OASIS application must be running on the scan tool during APIM programming. To carry out
APIM programming, refer to Accessory Protocol Interface Module (APIM) Programming See:
Programming and Relearning/Accessory Protocol Interface Module (APIM) Programming.
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 Block
Some PCMs contain a memory area called a vehicle identification block. The PCM vehicle
identification block commonly stores powertrain configuration items such as Vehicle Identification
Number (VIN), tire size, axle ratio, and whether or not the vehicle is equipped with speed control.
Module Address
A unique module address is assigned to each module on the network for identification.
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 does not reflect
customer preference items that have been changed from the default state. These items 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 As-Built data addresses and describes specific module configuration
information:
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Module Configuration and Parameter Chart (Part 1)
Module Configuration and Parameter Chart (Part 2)
Inspection And Verification
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Module Configuration
Inspection and Verification
This provides step-by-step module configuration procedures. Carry out the Programmable Module
Installation (PMI) procedure when another diagnostic/repair information directs to carry out
configuration or when DTCs from the below list are present: See: Programming and Relearning
NOTE: Some of these modules utilize a 5-character DTC followed by a 2-character failure-type
code. The failure-type code provides information about specific fault conditions such as opens, or
shorts to ground. Continuous memory DTCs have an additional 2-character DTC status code suffix
to assist in determining DTC history.
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Information Bus: Diagnostic Trouble Code Descriptions
Communications Network
Communications Network
DTC Charts
NOTE: Network DTCs (U-codes) are often a result of intermittent concerns such as damaged
wiring or low battery voltage occurrences. Additionally, vehicle service procedures such as module
reprogramming will often set network DTCs. Replacing a module to resolve a network DTC is
unlikely to resolve the concern. To prevent repeat network DTC concerns, inspect all network
wiring, especially connectors. Test the vehicle battery, refer to Battery.
NOTE: Some modules on this vehicle utilize a 5-character DTC followed by a 2-character
failure-type code. The failure-type code provides information about specific fault conditions such as
opens, or shorts to ground. Continuous memory DTCs have an additional 2-character DTC status
code suffix to assist in determining DTC history.
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U0073-U0155
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U016A:00-U0196
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U046B:00-U1900
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U1900-U3000:88
Module Configuration
Module Configuration
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B2477-B2900 / P0602-P1639 / U201A:51-U2050
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U2051-U2101:00
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Information Bus: Symptom Related Diagnostic Procedures
Communications Network
Symptom Chart
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
Pinpoint Test A: The PCM Does Not Respond To The Scan Tool
Communications Network
Pinpoint Tests
Pinpoint Test A: The PCM Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 23, Electronic Engine Controls - 4.0L for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 24, Electronic Engine Controls - 4.6L for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
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.
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- PCM
PINPOINT TEST A: THE PCM DOES NOT RESPOND TO THE SCAN TOOL
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- A1 VERIFY WHETHER OTHER HS-CAN MODULES PASS
THE NETWORK TEST
- Enter the following diagnostic mode on the scan tool: Network Test.
- In the left hand pane of the Integrated Diagnostic System (IDS) network test display screen, verify
whether any HS-CAN modules passed the network test.
- Is the text "pass" or a DTC listed next to any of the following modules (if equipped): 4x4 control
module, ABS module, Accessory Protocol Interface Module (APIM), Instrument Cluster (IC),
Occupant Classification System Module (OCSM), PCM or Restraints Control Module (RCM)?
Yes
If "pass" or a DTC was listed next to the PCM, a network fault is not currently present. Go To
Pinpoint Test T to diagnose an intermittent HS-CAN fault condition. See: Pinpoint Test T:
Intermittent No High Speed Controller Area Network (HS-CAN) Communication, One Or More
Modules Are Not Respond
If "pass" or a DTC was listed next to one or more modules other than the PCM, GO to A2.
No
No modules are currently communicating on the HS-CAN. Go To Pinpoint Test s to diagnose no
HS-CAN communication. See: Pinpoint Test S: No High Speed Controller Area Network (HS-CAN)
Communication, All Modules Are Not Responding
------------------------------------------------- A2 COMPUTERS AND CONTROL SYSTEMS
INFORMATION PINPOINT TEST QA VERIFICATION CHECK
- Verify that pinpoint test QA has been performed.
- Has pinpoint test QA been performed?
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Yes
GO to A3.
No
REFER to Computers and Control Systems Information, Pinpoint Tests, pinpoint test QA to
diagnose no communication with the PCM.
------------------------------------------------- A3 CHECK THE HS-CAN TERMINATION RESISTANCE
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the Data Link Connector (DLC) C251-6, circuit VDB04 (WH/BU),
harness side and the DLC C251-14, circuit VDB05 (WH), harness side.
- Is the resistance between 54 and 66 ohms?
Yes
CONNECT the negative battery cable. GO to A5.
No
GO to A4.
------------------------------------------------- A4 CHECK THE CAN CIRCUITS BETWEEN THE DLC AND
THE PCM FOR AN OPEN
- Disconnect: PCM C175b.
- Measure the resistance between the PCM C175b-11, circuit VDB04 (WH/BU), harness side and
the DLC C251-6, circuit VDB04 (WH/BU), harness side.
- Measure the resistance between the PCM C175b-23, circuit VDB05 (WH), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to A5.
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No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- A5 CHECK FOR CORRECT PCM OPERATION
- Disconnect all the PCM connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the PCM connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new PCM. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------Pinpoint Test B: The Transmission Control Module (TCM) Does Not Respond To The Scan Tool
Communications Network
Pinpoint Tests
Pinpoint Test B: The Transmission Control Module (TCM) Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 30, Transmission Controls - 6R60 for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
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. 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
PINPOINT TEST B: THE TCM DOES NOT RESPOND TO THE SCAN TOOL
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- B1 CHECK THE TCM VOLTAGE SUPPLY CIRCUITS FOR
AN OPEN
- Ignition OFF.
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- Disconnect: TCM C1575 (6R60 Transmission).
- Ignition ON.
- Measure the voltage between the TCM C1575-9, circuit CE517 (BU/GN), harness side and
ground; and between the TCM C1575-14, circuit SBB27 (BU/RD), harness side and ground
- Are the voltages greater than 10 volts?
Yes
GO to B2.
No
VERIFY that the Battery Junction Box (BJB) fuse 27 (20A) or Smart Junction Box (SJB) fuse 9 (2A)
is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify
the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan
tool.
------------------------------------------------- B2 CHECK THE TCM GROUND CIRCUITS FOR AN OPEN
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the TCM C1575-13, circuit GD113 (BK/YE), harness side and
ground; and between the TCM C1575-16, circuit GD113 (BK/YE), harness side and ground.
Are the resistances less than 5 ohms?
Yes
GO to B3.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- B3 CHECK THE HS-CAN CIRCUITS BETWEEN THE TCM
AND THE DLC FOR AN OPEN
- Measure the resistance between the TCM C1575-6, circuit VDB04 (WH/BU), harness side and
the DLC C251-6, circuit VDB04 (WH/BU), harness side.
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2869
- Measure the resistance between the TCM C1575-2, circuit VDB05 (WH), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to B4.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- B4 CHECK FOR CORRECT TCM OPERATION
- Disconnect the TCM connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the TCM connector and make sure it seats correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new TCM. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------Pinpoint Test C: The ABS Module Does Not Respond To The Scan Tool
Communications Network
Pinpoint Tests
Pinpoint Test C: The ABS Module Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 42, Vehicle Dynamic Systems for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2870
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. 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
PINPOINT TEST C: THE ABS MODULE DOES NOT RESPOND TO THE SCAN TOOL
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- C1 CHECK THE ABS VOLTAGE SUPPLY CIRCUITS FOR
AN OPEN
- Ignition OFF.
- Disconnect: ABS Module C155.
- Ignition ON.
- Measure the voltage between the ABS module, harness side and ground as follows:
- Are the voltages greater than 10 volts?
Yes
GO to C2.
No
VERIFY the Battery Junction Box (BJB) fuse 6 (40A) or fuse 33 (30A) and the Smart Junction Box
(SJB) fuse 18 (10A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring
Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the
network test with the scan tool.
------------------------------------------------- C2 CHECK THE ABS GROUND CIRCUIT FOR AN OPEN
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the ABS module C155-16, circuit GD120 (BK/GN) harness side
and ground.
- Is the resistance less than 5 ohms?
Yes
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2871
GO to C3.
No
REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network
test with the scan tool.
------------------------------------------------- C3 CHECK THE HS-CAN CIRCUITS BETWEEN THE ABS
MODULE AND THE DLC FOR AN OPEN
- Measure the resistance between the ABS module C135-12, circuit VDB04 (WH/BU), harness side
and the DLC C251-6, circuit VDB04 (WH/BU), harness side.
- Measure the resistance between the ABS module C135-13, circuit VDB05 (WH), harness side
and the DLC C251-14, circuit VDB05 (WH), harness side.
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to C4.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- C4 CHECK FOR CORRECT ABS MODULE OPERATION
- Disconnect the ABS module connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the ABS module connector and make sure it seats correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new ABS module. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------Pinpoint Test D: The Restraints Control Module (RCM) Does Not Respond To The Scan Tool
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2872
Communications Network
Pinpoint Tests
Pinpoint Test D: The Restraints Control Module (RCM) Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 46, Supplemental Restraint System for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
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. 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
- Case ground open
- RCM
PINPOINT TEST D: THE RCM DOES NOT RESPOND TO THE SCAN TOOL
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
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.
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection
and verification before proceeding with the pinpoint test. See: Initial Inspection and Diagnostic
Overview/Communications Network/Inspection And Verification
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- D1 CHECK THE RCM CONNECTION
- Ignition OFF.
- Depower the SRS. Refer to Air Bag Systems.
- Disconnect: RCM C310a.
- Disconnect: RCM C310b.
- Are RCM C310a pin 24 and RCM C310b pins 17 and 18 OK?
Yes
GO to D2.
No
REPAIR the RCM connector pins as necessary. REPOWER the SRS. REFER to Air Bag Systems.
CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- D2 CHECK THE RCM VOLTAGE SUPPLY CIRCUIT FOR
AN OPEN
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2873
- Deactivate the SRS. Refer to Air Bag Systems.
- Repower the SRS. Refer to Air Bag Systems.
- Ignition ON.
- Measure the voltage between the RCM C310a-24, circuit CBP17 (BN/GN), harness side and
ground.
- Is the voltage greater than 10 volts?
Yes
GO to D3.
No
VERIFY the Smart Junction Box (SJB) fuse 17 (10A) is OK. If OK, REPAIR the circuit. If not OK,
REFER to the Wiring Diagrams to identify the possible causes of the circuit short. REACTIVATE
the SRS. REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan
tool.
------------------------------------------------- D3 CHECK THE RCM CASE GROUND
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the RCM case and a good chassis ground.
- Is the resistance less than 5 ohms?
Yes
GO to D4.
No
REPAIR the RCM case ground as necessary. CONNECT the negative battery cable.
REACTIVATE the SRS. REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test
with the scan tool.
------------------------------------------------- D4 CHECK THE HS-CAN CIRCUITS BETWEEN THE RCM
AND THE DLC FOR AN OPEN
- Measure the resistance between the RCM C310b-18, circuit VDB04 (WH/BU), harness side and
the DLC C251-6, circuit VDB04 (WH/BU), harness side.
- Measure the resistance between the RCM C310b-17, circuit VDB05 (WH), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2874
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to D5.
No
REPAIR the circuit in question. CONNECT the negative battery cable. REACTIVATE the SRS.
REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- D5 CHECK FOR CORRECT RCM OPERATION
- Disconnect all the RCM connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the RCM connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
Is the concern still present?
Yes
INSTALL a new RCM. REACTIVATE the SRS. REFER to Air Bag Systems. CLEAR the DTCs.
REPEAT the network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. REACTIVATE the SRS. REFER to Air Bag Systems. CLEAR the DTCs.
REPEAT the network test with the scan tool.
------------------------------------------------Pinpoint Test E: The 4X4 Control Module Does Not Respond To The Scan Tool
Communications Network
Pinpoint Tests
Pinpoint Test E: The 4X4 Control Module Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 34, Four Wheel Drive Systems for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
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. 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2875
- 4X4 control module
PINPOINT TEST E: THE 4X4 CONTROL MODULE DOES NOT RESPOND TO THE SCAN TOOL
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- E1 CHECK THE 4X4 CONTROL MODULE VOLTAGE
SUPPLY CIRCUITS FOR AN OPEN
- Ignition OFF.
- Disconnect: 4X4 Control Module C281a.
- Disconnect: 4X4 Control Module C281b.
- Ignition ON.
- Measure the voltage between the 4X4 control module, harness side and ground as follows:
- Are the voltages greater than 10 volts?
Yes
GO to E2.
No
VERIFY the Battery Junction Box (BJB) fuse 23 (20A) or fuse 26 (20A) is OK and the Smart
Junction Box (SJB) fuse 18 (10A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to
the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- E2 CHECK THE 4X4 CONTROL MODULE GROUND
CIRCUITS FOR AN OPEN
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the 4X4 control module, harness side and ground as follows:
- Are the resistances less than 5 ohms?
Yes
GO to E3.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- E3 CHECK THE HS-CAN CIRCUITS BETWEEN THE 4X4
CONTROL MODULE AND THE DLC FOR AN OPEN
- Measure the resistance between the 4X4 control module C281a-10, circuit VDB04 (WH/BU),
harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side.
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- Measure the resistance between the 4X4 control module C281a-9, circuit VDB05 (WH), harness
side and the DLC C251-14, circuit VDB05 (WH), harness side.
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to E4.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- E4 CHECK FOR CORRECT 4X4 CONTROL MODULE
OPERATION
- Disconnect all the 4X4 control module connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the 4X4 control module connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new 4X4 control module. CLEAR the DTCs. REPEAT the network test with the scan
tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------Pinpoint Test F: The Occupant Classification System Module (OCSM) Does Not Respond To The
Scan Tool
Communications Network
Pinpoint Tests
Pinpoint Test F: The Occupant Classification System Module (OCSM) Does Not Respond To The
Scan Tool
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2877
Refer to Wiring Diagram Set 46, Supplemental Restraint System for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
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. 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
PINPOINT TEST F: THE OCSM DOES NOT RESPOND TO THE SCAN TOOL
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection
and verification before proceeding with the pinpoint test. See: Initial Inspection and Diagnostic
Overview/Communications Network/Inspection And Verification
------------------------------------------------- F1 CHECK THE OCSM VOLTAGE SUPPLY CIRCUIT FOR
AN OPEN
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.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
- Ignition OFF.
- Depower the SRS. Refer to Air Bag Systems.
- Disconnect: OCSM C3159.
- Deactivate the SRS. Refer to Air Bag Systems.
- Repower the SRS. Refer to Air Bag Systems.
- Ignition ON.
- Measure the voltage between the OCSM C3159-1, circuit CBP17 (BN/GN), harness side and
ground.
- Is the voltage greater than 10 volts?
Yes
GO to F2.
No
VERIFY the Smart Junction Box (SJB) fuse 17 (10A) is OK. If OK, REPAIR the circuit. If not OK,
REFER to the Wiring Diagrams to identify the possible causes of the circuit short. REACTIVATE
the SRS. REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan
tool.
------------------------------------------------- F2 CHECK THE OCSM GROUND CIRCUIT FOR AN OPEN
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2878
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the OCSM C3159-14, circuit GD145 (BK/BU), harness side and
ground.
- Is the resistance less than 5 ohms?
Yes
GO to F3.
No
REPAIR the circuit. CONNECT the negative battery cable. REACTIVATE the SRS. REFER to Air
Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- F3 CHECK THE HS-CAN CIRCUITS BETWEEN THE OCSM
AND THE DLC FOR AN OPEN
- Measure the resistance between the OCSM C3159-18, circuit VDB04 (WH/BU), harness side and
the DLC C251-6, circuit VDB04 (WH/BU), harness side.
- Measure the resistance between the OCSM C3159-9, circuit VDB05 (WH), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to F4.
No
REPAIR the circuit. REACTIVATE the SRS. REFER to Air Bag Systems. CONNECT the negative
battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- F4 CHECK FOR CORRECT OCSM OPERATION
- Disconnect the OCSM connector.
- Check for:
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2879
- corrosion
- damaged pins
- pushed-out pins
- Connect the OCSM connector and make sure it seats correctly.
- Verify the concern is still present.
Is the concern still present?
Yes
INSTALL a new OCSM. REACTIVATE the SRS. REFER to Air Bag Systems. CLEAR the DTCs.
REPEAT the network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. REACTIVATE the SRS. REFER to Air Bag Systems. CLEAR the DTCs.
REPEAT the network test with the scan tool.
------------------------------------------------Pinpoint Test G: The Instrument Cluster (IC) Does Not Respond To The Scan Tool
Communications Network
Pinpoint Tests
Pinpoint Test G: The Instrument Cluster (IC) Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 60, Instrument Cluster for schematic and connector information. See:
Diagrams/Electrical Diagrams/Diagrams By Number
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. 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
PINPOINT TEST G: THE IC DOES NOT RESPOND TO THE SCAN TOOL
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- G1 CHECK THE HS-CAN TERMINATION RESISTANCE
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Disconnect the scan tool cable from the Data Link Connector (DLC).
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2880
- Is the resistance between 54 and 66 ohms?
Yes
GO to G2.
No
GO to G4.
------------------------------------------------- G2 CHECK THE IC GROUND CIRCUIT FOR AN OPEN
- Measure the resistance between the IC C220-13, circuit GD145 (BK/BU), harness side and
ground.
- Is the resistance less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to G3.
No
REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network
test with the scan tool.
------------------------------------------------- G3 CHECK THE IC VOLTAGE SUPPLY CIRCUITS FOR AN
OPEN
- Disconnect: IC C220.
- Ignition ON.
- Measure the voltage between the IC, harness side and ground as follows:
- Are the voltages greater than 10 volts?
Yes
GO to G5.
No
VERIFY the Smart Junction Box (SJB) fuse 8 (15A) or fuse 24 (10A) is OK. If OK, REPAIR the
circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the
circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- G4 CHECK THE HS-CAN CIRCUITS BETWEEN THE IC
AND THE DLC FOR AN OPEN
- Measure the resistance between the IC C220-7, circuit VDB04 (WH/BU), harness side and the
DLC C251-6, circuit VDB04 (WH/BU), harness side.
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2881
- Measure the resistance between the IC C220-8, circuit VDB05 (WH), harness side and the DLC
C251-14, circuit VDB05 (WH), harness side.
- Are the resistances less than 5 ohms?
Yes
GO to G5.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- G5 CHECK THE MS-CAN CIRCUITS BETWEEN THE IC
AND THE DLC FOR AN OPEN
- Measure the resistance between the IC C220-4, circuit VDB06 (GY/OG), harness side and the
DLC C251-3, circuit VDB06 (GY/OG), harness side.
- Measure the resistance between the IC C220-5, circuit VDB07 (VT/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to G6.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
-------------------------------------------------
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2882
G6 CHECK FOR CORRECT IC OPERATION
- Disconnect the IC connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the IC connector and make sure it seats correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new IC. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------Pinpoint Test H: The Smart Junction Box (SJB) Does Not Respond To The Scan Tool
Communications Network
Pinpoint Tests
Pinpoint Test H: The Smart Junction Box (SJB) Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 10, Grounds for schematic and connector information. See:
Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 13, Power Distribution/SJB for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
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. 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
PINPOINT TEST H: THE SJB DOES NOT RESPOND TO THE SCAN TOOL
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
------------------------------------------------- H1 CHECK THE SJB FUSE FOR VOLTAGE
- Ignition OFF.
- NOTE: Measurements are taken with the fuses installed.
- Measure the voltage between the SJB fuse 2 (5A) and ground.
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- Are the voltages greater than 10 volts?
Yes
GO to H3.
No
VERIFY the Smart Junction Box (SJB) fuse 2 (5A) is OK. If OK, GO to H2. If not OK, REFER to the
Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the
network test with the scan tool.
------------------------------------------------- H2 CHECK THE SJB VOLTAGE SUPPLY CIRCUIT FOR AN
OPEN
- Disconnect: SJB C2280e.
- Measure the voltage between the SJB C2280e-1, circuit SBB03 (BU/RD), harness side and
ground.
- Is the voltage greater than 10 volts?
Yes
GO to H5.
No
VERIFY the Battery Junction Box (BJB) fuse 3 (50A) is OK. If OK, REPAIR the circuit. If not OK,
REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the
DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- H3 CHECK THE SJB GROUND CIRCUIT FOR AN OPEN
- Disconnect: Negative Battery Cable.
- Disconnect: SJB C2280e.
- Measure the resistance between the SJB C2280e-22, circuit GD108 (BK/VT), harness side and
ground.
- Is the resistance less than 5 ohms?
Yes
GO to H4.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2884
No
REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network
test with the scan tool.
------------------------------------------------- H4 CHECK THE MEDIUM SPEED CAN CIRCUITS
BETWEEN THE SJB AND THE DLC FOR AN OPEN
- Disconnect: SJB C2280d.
- Measure the resistance between the SJB C2280d-16, circuit VDB06 (GY/OG), harness side and
the DLC C251-3, circuit VDB06 (GY/OG), harness side.
- Measure the resistance between the SJB C2280d-15, circuit VDB07 (VT/OG), harness side and
the DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to H5.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- H5 CHECK FOR CORRECT SJB OPERATION
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new SJB. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------Pinpoint Test I: The HVAC Module Does Not Respond To The Scan Tool
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2885
Communications Network
Pinpoint Tests
Pinpoint Test I: The HVAC Module Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 55, Automatic Climate Control System for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Normal Operation
The 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. 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
- HVAC module
PINPOINT TEST I: THE HVAC MODULE DOES NOT RESPOND TO THE SCAN TOOL
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- I1 CHECK THE HVAC MODULE VOLTAGE SUPPLY
CIRCUITS FOR AN OPEN
- Ignition OFF.
- Disconnect: HVAC Module C228a.
- Ignition ON.
- Measure the voltage between the HVAC module C228a-13, circuit SBP28 (GN/RD), and between
the HVAC module C228a-3, circuit CBP20 (YE/VT) and ground.
- Are the voltages greater than 10 volts?
Yes
GO to I2.
No
VERIFY the Smart Junction Box (SJB) fuse 20 (10A) or fuse 28 (10A) is OK. If OK, REPAIR the
circuit in question. CLEAR the DTCs. If not OK, REFER to the Wiring Diagrams to identify the
possible causes of the circuit short. REPEAT the network test with the scan tool.
------------------------------------------------- I2 CHECK THE HVAC GROUND CIRCUIT FOR AN OPEN
- Ignition OFF.
- Disconnect: Negative Battery Cable.
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2886
- Measure the resistance between the HVAC module C228a-2, circuit GD145 (BK/BU) and ground.
- Is the resistance less than 5 ohms?
Yes
GO to I3.
No
REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network
test with the scan tool.
------------------------------------------------- I3 CHECK THE MS-CAN CIRCUITS BETWEEN THE HVAC
MODULE AND THE DLC FOR AN OPEN
- Measure the resistance between the HVAC module C228a-11, circuit VDB06 (GY/OG), harness
side and the DLC C251-3, circuit VDB06 (GY/OG), harness side.
- Measure the resistance between the HVAC module C228a-1, circuit VDB07 (VT/OG), harness
side and the DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to I4.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- I4 CHECK FOR CORRECT HVAC MODULE OPERATION
- Disconnect all the HVAC module connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the HVAC module connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2887
- Is the concern still present?
Yes
INSTALL a new HVAC module. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------Pinpoint Test J: The Audio Control Module (ACM) Does Not Respond To The Scan Tool
Communications Network
Pinpoint Tests
Pinpoint Test J: The Audio Control Module (ACM) Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 130, Audio System/Navigation for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Normal Operation
Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network
connection to the Audio Control Module (ACM). 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
PINPOINT TEST J: THE ACM DOES NOT RESPOND TO THE SCAN TOOL
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- J1 CHECK THE ACM VOLTAGE SUPPLY CIRCUITS FOR
AN OPEN
- Ignition OFF.
- Disconnect: ACM C290a.
- Ignition ON.
- Measure the voltage between the ACM C290a-1, circuit SBP03 (BU/RD), harness side and
ground; and between the ACM C290a-2, circuit CBP12 (GN/WH), harness side and ground.
- Are the voltages greater than 10 volts?
Yes
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2888
GO to J2.
No
VERIFY the Smart Junction Box (SJB) fuse 3 (20A) or fuse 12 (5A) is OK. If OK, REPAIR the
circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the
circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- J2 CHECK THE ACM GROUND CIRCUIT FOR AN OPEN
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the ACM C290a-13, circuit GD114 (BK/BU), harness side and
ground.
- Is the resistance less than 5 ohms?
Yes
GO to J3.
No
REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network
test with the scan tool.
------------------------------------------------- J3 CHECK THE MS-CAN CIRCUITS BETWEEN THE ACM
AND THE DLC FOR AN OPEN
- Measure the resistance between the ACM C290b-15, circuit VDB06 (GY/OG), harness side and
the DLC C251-3, circuit VDB06 (GY/OG), harness side.
- Measure the resistance between the base ACM C290b-16, circuit VDB07 (VT/OG), harness side
and the DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to J4.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- J4 CHECK FOR CORRECT ACM OPERATION
- Disconnect all the ACM connectors.
- Check for:
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2889
- corrosion
- damaged pins
- pushed-out pins
- Connect all the ACM connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
Is the concern still present?
Yes
INSTALL a new ACM. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------Pinpoint Test K: The Satellite Digital Audio Receiver System (SDARS) Module Does Not Respond
To The Scan Tool
Communications Network
Pinpoint Tests
Pinpoint Test K: The Satellite Digital Audio Receiver System (SDARS) Module Does Not Respond
To The Scan Tool
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 130, Audio System/Navigation for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
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. 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
PINPOINT TEST K: THE SDARS MODULE DOES NOT RESPOND TO THE SCAN TOOL
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- K1 CHECK THE SDARS MODULE VOLTAGE SUPPLY
CIRCUIT FOR AN OPEN
- Ignition OFF.
- Disconnect: SDARS Module C3290.
- Ignition ON.
- Measure the voltage between the SDARS module C3290-9, circuit SBB41 (RD), harness side and
ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2890
- Is the voltage greater than 10 volts?
Yes
GO to K2.
No
VERIFY the Battery Junction Box (BJB) fuse 41 (15A) is OK. If OK, REPAIR the circuit in question.
If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short.
CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- K2 CHECK THE SDARS MODULE GROUND CIRCUIT FOR
AN OPEN
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the SDARS module C3290-3, circuit GD114 (BK/BU), harness
side and ground.
- Is the resistance less than 5 ohms?
Yes
GO to K3.
No
REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network
test with the scan tool.
------------------------------------------------- K3 CHECK THE MS-CAN CIRCUITS BETWEEN THE
SDARS MODULE AND THE DLC FOR AN OPEN
- Measure the resistance between the SDARS module C3290-1, circuit VDB06 (GY/OG), harness
side and the DLC C251-3, circuit VDB06 (GY/OG), harness side.
- Measure the resistance between the SDARS module C3290-7, circuit VDB07 (VT/OG), harness
side and the DLC C251-11, circuit VDB07 (VT/OG), harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2891
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to K4.
No
REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network
test with the scan tool.
------------------------------------------------- K4 CHECK FOR CORRECT SDARS MODULE OPERATION
- Disconnect the SDARS module connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the SDARS module connector and make sure it seats correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new SDARS module. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------Pinpoint Test L: The Rear Entertainment Module (RETM) Does Not Respond To The Scan Tool
Communications Network
Pinpoint Tests
Pinpoint Test L: The Rear Entertainment Module (RETM) Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 130, Audio System/Navigation for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
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. 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2892
PINPOINT TEST L: THE RETM DOES NOT RESPOND TO THE SCAN TOOL
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- L1 CHECK THE RETM VOLTAGE SUPPLY CIRCUIT FOR
AN OPEN
- Ignition OFF.
- Disconnect: RETM C9029.
- Ignition ON.
- Measure the voltage between the RETM C9029-16, circuit SBB41 (RD), harness side and
ground.
- Is the voltage greater than 10 volts?
Yes
GO to L2.
No
VERIFY the Battery Junction Box (BJB) fuse 41 (15A) is OK. If OK, REPAIR the circuit. If not OK,
REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the
DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- L2 CHECK THE RETM GROUND CIRCUIT FOR AN OPEN
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the RETM C9029-1, circuit GD114 (BK/BU), harness side and
ground.
- Is the resistance less than 5 ohms?
Yes
GO to L3.
No
REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network
test with the scan tool.
------------------------------------------------- L3 CHECK THE MS-CAN CIRCUITS BETWEEN THE RETM
AND THE DLC FOR AN OPEN
- Measure the resistance between the RETM C9029-8, circuit VDB06 (GY/OG), harness side and
the DLC C251-3, circuit VDB06 (GY/OG), harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2893
- Measure the resistance between the RETM C9029-7, circuit VDB07 (VT/OG), harness side and
the DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to L4.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- L4 CHECK FOR CORRECT RETM OPERATION
- Disconnect the RETM connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the RETM connector and make sure it seats correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new RETM. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------Pinpoint Test M: The Driver Seat Module (DSM) Does Not Respond To The Scan Tool
Communications Network
Pinpoint Tests
Pinpoint Test M: The Driver Seat Module (DSM) Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 123, Memory Seats for schematic and connector information. See:
Diagrams/Electrical Diagrams/Diagrams By Number
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2894
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. 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
PINPOINT TEST M: THE DSM DOES NOT RESPOND TO THE SCAN TOOL
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- M1 CHECK THE DSM VOLTAGE SUPPLY CIRCUIT FOR
AN OPEN
- Ignition OFF.
- Disconnect: DSM C341c.
- Ignition ON.
- Measure the voltage between the DSM C341c-1, circuit SBP01 (RD), harness side and ground.
- Is the voltage greater than 10 volts?
Yes
GO to M2.
No
VERIFY the Smart Junction Box (SJB) fuse 1 (20A) is OK. If OK, REPAIR the circuit. If not OK,
REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the
DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- M2 CHECK THE DSM GROUND CIRCUIT FOR AN OPEN
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the DSM C341c-13, circuit GD143 (BK/OG), harness side and
ground.
- Is the resistance less than 5 ohms?
Yes
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2895
GO to M3.
No
REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network
test with the scan tool.
------------------------------------------------- M3 CHECK THE MS-CAN CIRCUITS BETWEEN THE DLC
AND THE DSM FOR AN OPEN
- Measure the resistance between the DSM C341c-11, circuit VDB06 (GY/OG), harness side and
the DLC C251-3, circuit VDB06 (GY/OG), harness side.
- Measure the resistance between the DSM C341c-12, circuit VDB07 (VT/OG), harness side and
the DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to M4.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- M4 CHECK FOR CORRECT DSM OPERATION
- Disconnect all the DSM connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the DSM connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new DSM. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------Pinpoint Test N: The Power Running Board Module Does Not Respond To The Scan Tool
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2896
Communications Network
Pinpoint Tests
Pinpoint Test N: The Power Running Board Module Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
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. 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
PINPOINT TEST N: THE PRB MODULE DOES NOT RESPOND TO THE SCAN TOOL
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- N1 CHECK THE PRB MODULE VOLTAGE SUPPLY
CIRCUIT FOR AN OPEN
- Ignition OFF.
- Disconnect: PRB Module C4322b.
- Ignition ON.
- Measure the voltage between the PRB module C4322b-1, circuit SBB19 (BU/RD), harness side
and ground.
- Is the voltage greater than 10 volts?
Yes
GO to N2.
No
VERIFY the Battery Junction Box (BJB) fuse 19 (30A) is OK. If OK, REPAIR the circuit. If not OK,
REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the
DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- N2 CHECK THE PRB MODULE GROUND CIRCUIT FOR
AN OPEN
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the PRB module C4322b-4, circuit GD151 (BK/GN), harness
side and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2897
- Is the resistance less than 5 ohms?
Yes
GO to N3.
No
REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network
test with the scan tool.
------------------------------------------------- N3 CHECK THE MS-CAN CIRCUITS BETWEEN THE PRB
MODULE AND THE DLC FOR AN OPEN
- Measure the resistance between the PRB module C4322b-8, circuit VDB06 (GY/OG), harness
side and the DLC C251-3, circuit VDB06 (GY/OG), harness side.
- Measure the resistance between the PRB module C4322b-7, circuit VDB07 (VT/OG), harness
side and the DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to N4.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- N4 CHECK FOR CORRECT PRB MODULE OPERATION
- Disconnect all the PRB module connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the PRB module connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2898
Yes
INSTALL a new PRB module. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------Pinpoint Test O: The Parking Aid Module (PAM) Does Not Respond To The Scan Tool
Communications Network
Pinpoint Tests
Pinpoint Test O: The Parking Aid Module (PAM) Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 131, Parking Aid for schematic and connector information. See:
Diagrams/Electrical Diagrams/Diagrams By Number
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. 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
PINPOINT TEST O: THE PAM DOES NOT RESPOND TO THE SCAN TOOL
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- O1 VERIFY PARKING AID SYSTEM TYPE
- NOTE: The Explorer uses a radar parking aid system while the Mountaineer and Explorer Sport
Trac use an ultrasonic system.
- Verify the parking aid system.
- Is the vehicle equipped with a RADAR parking aid system?
Yes
GO to O2.
No
GO to O5 .
------------------------------------------------- O2 CHECK THE PAM VOLTAGE SUPPLY CIRCUIT FOR
AN OPEN (RADAR)
- Ignition OFF.
- Disconnect: PAM C4226.
- Ignition ON.
- Measure the voltage between the PAM C4226-18, circuit CBP18 (GY/OG), harness side and
ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2899
- Is the voltage greater than 10 volts?
Yes
GO to O3.
No
VERIFY the Smart Junction Box (SJB) fuse 18 (10A) is OK. If OK, REPAIR the circuit. If not OK,
REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the
DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- O3 CHECK THE PAM GROUND CIRCUIT FOR AN OPEN
(RADAR)
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the PAM C4226-6, circuit GD145 (BK/BU), harness side and
ground.
- Is the resistance less than 5 ohms?
Yes
GO to O4.
No
REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network
test with the scan tool.
------------------------------------------------- O4 CHECK THE MS-CAN CIRCUITS BETWEEN THE PAM
AND THE DLC FOR AN OPEN (RADAR)
- Measure the resistance between the PAM C4226-4, circuit VDB06 (GY/OG), harness side and
the DLC C251-3, circuit VDB06 (GY/OG), harness side.
- Measure the resistance between the PAM C4226-5, circuit VDB07 (VT/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2900
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to O8.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- O5 CHECK THE PAM VOLTAGE SUPPLY CIRCUIT FOR
AN OPEN (ULTRASONIC)
- Ignition OFF.
- Disconnect: PAM C4014 (Mountaineer) or C3267 (Explorer Sport Trac).
- Ignition ON.
- Measure the voltage between the PAM C4014-1 (Mountaineer) or C3267-1 (Explorer Sport Trac),
circuit CBP18 (GY/OG), harness side and ground.
Is the voltage greater than 10 volts?
Yes
GO to O6.
No
VERIFY the Smart Junction Box (SJB) fuse 18 (10A) is OK. If OK, REPAIR the circuit. If not OK,
REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the
DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- O6 CHECK THE PAM GROUND CIRCUIT FOR AN OPEN
(ULTRASONIC)
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the PAM C4014-4 (Mountaineer) or C3267-4 (Explorer Sport
Trac), circuit GD145 (BK/BU), harness side and ground.
- Is the resistance less than 5 ohms?
Yes
GO to O7.
No
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2901
REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network
test with the scan tool.
------------------------------------------------- O7 CHECK THE MS-CAN CIRCUITS BETWEEN THE PAM
AND THE DLC FOR AN OPEN (ULTRASONIC)
- Measure the resistance between the PAM C4014-3 (Mountaineer) or C3267-3 (Explorer Sport
Trac), circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness
side.
- Measure the resistance between the PAM C4014-11 (Mountaineer) or C3267-11 (Explorer Sport
Trac), circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG),
harness side.
Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to O8.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- O8 CHECK FOR CORRECT PAM OPERATION
- Disconnect the PAM connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the PAM connector and make sure it seats correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new PAM. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------Pinpoint Test P: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan
Tool
Communications Network
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2902
Pinpoint Tests
Pinpoint Test P: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan
Tool
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Normal Operation
The Accessory Protocol Interface Module (APIM) 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 APIM. Circuits VDB06 (GY/OG) (MS-CAN
+) and VDB07 (VT/OG) (MS-CAN -) provide the MS-CAN connection to the APIM. Voltage for the
APIM 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
- APIM
PINPOINT TEST P: THE APIM DOES NOT RESPOND TO THE SCAN TOOL
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- P1 CHECK THE APIM VOLTAGE SUPPLY CIRCUIT FOR
AN OPEN
- Disconnect: APIM C3342.
- Ignition ON.
- Measure the voltage between the APIM C3342-1, circuit SBB41 (RD), harness side and ground.
- Is the voltage greater than 10 volts?
Yes
GO to P2.
No
VERIFY the BJB fuse 41 (15A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to
the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- P2 CHECK THE APIM GROUND CIRCUITS FOR AN OPEN
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the APIM C3342-37, circuit GD114 (BK/BU), harness side and
ground; and between the APIM C3342-38, circuit GD114 (BK/BU), harness side and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2903
- Are the resistances less than 5 ohms?
Yes
GO to P3.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- P3 CHECK THE HS-CAN CIRCUITS BETWEEN THE APIM
AND THE DLC FOR AN OPEN
- Measure the resistance between the APIM C3342-53, circuit VDB04 (WH/BU), harness side and
the DLC C251-6, circuit VDB04 (WH/BU), harness side.
- Measure the resistance between the APIM C3342-54, circuit VDB05 (WH), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
- Are the resistances less than 5 ohms?
Yes
GO to P4.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- P4 CHECK THE MS-CAN CIRCUITS BETWEEN THE DLC
AND THE APIM FOR AN OPEN
- Measure the resistance between the APIM C3342-16, circuit VDB06 (GY/OG), harness side and
the DLC C251-3, circuit VDB06 (GY/OG), harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2904
- Measure the resistance between the APIM C3342-17, circuit VDB07 (VT/OG), harness side and
the DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to P5.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- P5 CHECK FOR CORRECT APIM OPERATION
- Disconnect all the APIM connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the APIM connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new APIM. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------Q1-Q27
Communications Network
Pinpoint Tests
Pinpoint Test Q: No Medium Speed Controller Area Network (MS-CAN) Communication, All
Modules Are Not Responding
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Normal Operation
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2905
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.
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- Accessory Protocol Interface Module (APIM) (if equipped)
- Audio Control Module (ACM)
- Driver Seat Module (DSM) (if equipped)
- HVAC module (if equipped)
- Instrument Cluster (IC)
- Parking Aid Module (PAM) (if equipped)
- Power Running Board (PRB) module (if equipped)
- Rear Entertainment Module (RETM) (if equipped)
- Satellite Digital Audio Receiver System (SDARS) module (if equipped)
- Smart Junction Box (SJB)
PINPOINT TEST Q: NO MS-CAN COMMUNICATION, ALL MODULES ARE NOT RESPONDING
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection
and verification before proceeding with the pinpoint test. See: Initial Inspection and Diagnostic
Overview/Communications Network/Inspection And Verification
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- Q1 CHECK THE DLC PINS FOR DAMAGE
- Ignition OFF.
- Disconnect the scan tool cable from the Data Link Connector (DLC).
- Inspect DLC pins 3 and 11 for damage.
- Are DLC pins 3 and 11 OK?
Yes
GO to Q2.
No
REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- Q2 CHECK THE MS-CAN TERMINATION RESISTANCE
- Disconnect: Negative Battery Cable.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Is the resistance between 54 and 66 ohms?
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2906
Yes
GO to Q3.
No
GO to Q5.
------------------------------------------------- Q3 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and
ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
GO to Q4.
No
GO to Q28.
------------------------------------------------- Q4 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TO VOLTAGE
- Connect: Negative Battery Cable.
- Ignition ON.
- Measure the voltage between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground;
and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground.
- Is the voltage greater than 6 volts?
Yes
REPAIR the circuit. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
The CAN has tested within specifications. Go To Pinpoint Test R to diagnose the intermittent
MS-CAN fault. See: Pinpoint Test R: Intermittent No Medium Speed Controller Area Network
(MS-CAN) Communication, One Or More Modules Are Not Respo
------------------------------------------------- Q5 CHECK THE MS-CAN TERMINATION RESISTOR
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2907
- Is the resistance between 108 and 132 ohms?
Yes
GO to Q6.
No
GO to Q9.
------------------------------------------------- Q6 CHECK THE MS-CAN TERMINATION RESISTOR WITH
THE SJB DISCONNECTED
- Disconnect: SJB C2280b.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Is the resistance between 108 and 132 ohms?
Yes
GO to Q7.
No
GO to Q8.
------------------------------------------------- Q7 CHECK THE MS-CAN CIRCUITS BETWEEN THE SJB
AND THE DLC FOR AN OPEN
- Measure the resistance between the SJB C2280d-16, circuit VDB06 (GY/OG), harness side and
the DLC C251-3, circuit VDB06 (GY/OG), harness side.
- Measure the resistance between the SJB C2280d-15, circuit VDB07 (VT/OG), harness side and
the DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Are the resistances less than 5 ohms?
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2908
Yes
CONNECT the negative battery cable. GO to Q54.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- Q8 CHECK THE MS-CAN CIRCUITS BETWEEN THE IC
AND THE DLC FOR AN OPEN
- Disconnect: IC C220.
- Measure the resistance between the IC C220-4, circuit VDB06 (GY/OG), harness side and the
DLC C251-3, circuit VDB06 (GY/OG), harness side.
- Measure the resistance between the IC C220-5, circuit VDB07 (VT/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to Q45.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- Q9 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to Q11.
No
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2909
GO to Q10.
------------------------------------------------- Q10 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR AN OPEN
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Is the resistance greater than 10,000 ohms?
Yes
REPAIR the DLC or REPAIR the circuit in question. CONNECT the negative battery cable. VERIFY
the scan tool operation on a substitute vehicle. CLEAR the DTCs. REPEAT the network test on the
suspect vehicle.
No
A capacitor internal to a module may still be draining causing irregular resistance readings. WAIT 5
minutes. REPEAT the pinpoint test.
------------------------------------------------- Q11 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE IC DISCONNECTED
- Disconnect: ICC220.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to Q12.
No
CONNECT the negative battery cable. GO to Q45.
------------------------------------------------- Q12 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE ACM DISCONNECTED
- Disconnect: ACMC290b.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to Q13.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2910
No
CONNECT the negative battery cable. GO to Q46.
------------------------------------------------- Q13 VERIFY VEHICLE EQUIPMENT - HVAC MODULE
- Inspect the vehicle for an HVAC module.
- Is the vehicle equipped with an HVAC module?
Yes
GO to Q14.
No
GO to Q15.
------------------------------------------------- Q14 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE HVAC MODULE DISCONNECTED
- Disconnect: HVAC Module C228a.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to Q15.
No
CONNECT the negative battery cable. GO to Q47.
------------------------------------------------- Q15 VERIFY VEHICLE EQUIPMENT - RETM
- Inspect the vehicle for an RETM.
- Is the vehicle equipped with an RETM?
Yes
GO to Q16.
No
GO to Q17.
------------------------------------------------- Q16 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE RETM DISCONNECTED
- Disconnect: RETM C9029.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2911
- Is the resistance less than 5 ohms?
Yes
GO to Q17.
No
CONNECT the negative battery cable. GO to Q48.
------------------------------------------------- Q17 VERIFY VEHICLE EQUIPMENT - DSM
- Inspect the vehicle for a DSM.
- Is the vehicle equipped with a DSM?
Yes
GO to Q18.
No
GO to Q19.
------------------------------------------------- Q18 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE DSM DISCONNECTED
- Disconnect: DSM C341c.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to Q19.
No
CONNECT the negative battery cable. GO to Q49.
------------------------------------------------- Q19 VERIFY VEHICLE EQUIPMENT - SDARS MODULE
- Inspect the vehicle for a SDARS module.
- Is the vehicle equipped with a SDARS module?
Yes
GO to Q20.
No
GO to Q21.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2912
------------------------------------------------- Q20 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE SDARS MODULE DISCONNECTED
- Disconnect: SDARS C3290.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to Q21.
No
CONNECT the negative battery cable. GO to Q50.
------------------------------------------------- Q21 VERIFY VEHICLE EQUIPMENT - PRB MODULE
- Inspect the vehicle for a PRB module.
- Is the vehicle equipped with a PRB module?
Yes
GO to Q22.
No
GO to Q23.
------------------------------------------------- Q22 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE PRB MODULE DISCONNECTED
- Disconnect: PRB Module C4322b.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to Q23.
No
CONNECT the negative battery cable. GO to Q51.
------------------------------------------------- Q23 VERIFY VEHICLE EQUIPMENT - PAM
- Inspect the vehicle for a PAM.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2913
- Is the vehicle equipped with a PAM?
Yes
GO to Q24.
No
GO to Q25.
------------------------------------------------- Q24 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE PAM DISCONNECTED
- Disconnect: PAM C4014 (Mountaineer), C3267 (Explorer Sport Trac) or C4226 (Explorer).
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to Q25.
No
CONNECT the negative battery cable. GO to Q52.
------------------------------------------------- Q25 VERIFY VEHICLE EQUIPMENT - APIM
- Inspect the vehicle for an APIM.
- Is the vehicle equipped with an APIM?
Yes
GO to Q26.
No
GO to Q27.
------------------------------------------------- Q26 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE APIM DISCONNECTED
- Disconnect: APIM C3342.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to Q27.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2914
No
CONNECT the negative battery cable.GO to Q53.
------------------------------------------------- Q27 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE SJB DISCONNECTED
- Disconnect: SJB C2280d.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Is the resistance less than 5 ohms?
Yes
REPAIR the circuit. CONNECT all modules. CONNECT the negative battery cable. CLEAR the
DTCs. REPEAT the network test with the scan tool.
No
CONNECT the negative battery cable. GO to Q54.
------------------------------------------------Q28-Q54
Communications Network
Pinpoint Tests
Pinpoint Test Q: No Medium Speed Controller Area Network (MS-CAN) Communication, All
Modules Are Not Responding
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
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.
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- Accessory Protocol Interface Module (APIM) (if equipped)
- Audio Control Module (ACM)
- Driver Seat Module (DSM) (if equipped)
- HVAC module (if equipped)
- Instrument Cluster (IC)
- Parking Aid Module (PAM) (if equipped)
- Power Running Board (PRB) module (if equipped)
- Rear Entertainment Module (RETM) (if equipped)
- Satellite Digital Audio Receiver System (SDARS) module (if equipped)
- Smart Junction Box (SJB)
PINPOINT TEST Q: NO MS-CAN COMMUNICATION, ALL MODULES ARE NOT RESPONDING
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection
and verification before proceeding with the pinpoint
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2915
test. See: Initial Inspection and Diagnostic Overview/Communications Network/Inspection And
Verification
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- Q28 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE IC DISCONNECTED
- Disconnect: ICC220.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and
ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to Q45.
No
GO to Q29.
------------------------------------------------- Q29 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE ACM DISCONNECTED
- Disconnect: ACM C290b.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and
ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to Q46.
No
GO to Q30.
------------------------------------------------- Q30 VERIFY VEHICLE EQUIPMENT - HVAC MODULE
- Inspect the vehicle for an HVAC module.
- Is the vehicle equipped with an HVAC module?
Yes
GO to Q31.
No
GO to Q32.
------------------------------------------------- Q31 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE HVAC MODULE
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2916
DISCONNECTED
- Disconnect: HVAC Module C228a.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and
ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to Q47.
No
GO to Q32.
------------------------------------------------- Q32 VERIFY VEHICLE EQUIPMENT - RETM
- Inspect the vehicle for a RETM.
- Is the vehicle equipped with a RETM?
Yes
GO to Q33.
No
GO to Q34.
------------------------------------------------- Q33 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE RETM DISCONNECTED
- Disconnect: RETM C9029.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and
ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to Q48.
No
GO to Q34.
------------------------------------------------- Q34 VERIFY VEHICLE EQUIPMENT - DSM
- Inspect the vehicle for a DSM.
Is the vehicle equipped with a DSM?
Yes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2917
GO to Q35.
No
GO to Q36.
------------------------------------------------- Q35 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE DSM DISCONNECTED
- Disconnect: DSM C341c.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and
ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to Q49.
No
GO to Q36.
------------------------------------------------- Q36 VERIFY VEHICLE EQUIPMENT - SDARS MODULE
- Inspect the vehicle for a SDARS module.
Is the vehicle equipped with a SDARS module?
Yes
GO to Q37.
No
GO to Q38.
------------------------------------------------- Q37 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE SDARS MODULE DISCONNECTED
- Disconnect: SDARS Module C3290.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and
ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to Q50.
No
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2918
GO to Q38.
------------------------------------------------- Q38 VERIFY VEHICLE EQUIPMENT - PRB MODULE
- Inspect the vehicle for a PRB module.
- Is the vehicle equipped with a PRB module?
Yes
GO to Q39.
No
GO to Q40.
------------------------------------------------- Q39 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE PRB MODULE DISCONNECTED
- Disconnect: PRB Module C4322b.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and
ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to Q51.
No
GO to Q40.
------------------------------------------------- Q40 VERIFY VEHICLE EQUIPMENT - PAM
- Inspect the vehicle for a PAM.
- Is the vehicle equipped with a PAM?
Yes
GO to Q41.
No
GO to Q42.
------------------------------------------------- Q41 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE PAM DISCONNECTED
- Disconnect: PAM C4014 (Mountaineer), C3267 (Explorer Sport Trac) or C4226 (Explorer).
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and
ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2919
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to Q52.
No
GO to Q42.
------------------------------------------------- Q42 VERIFY VEHICLE EQUIPMENT - APIM
- Inspect the vehicle for an APIM.
- Is the vehicle equipped with an APIM?
Yes
GO to Q43.
No
GO to Q44.
------------------------------------------------- Q43 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE APIM DISCONNECTED
- Disconnect: APIM C3342.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and
ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to Q53.
No
GO to Q44.
------------------------------------------------- Q44 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE SJB DISCONNECTED
- Disconnect: SJB C2280d.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and
ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to Q54.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2920
No
REPAIR the circuit in question. CONNECT all modules. CONNECT the negative battery cable.
CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- Q45 CHECK FOR CORRECT IC OPERATION
- Disconnect the IC connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the IC connector and make sure it seats correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new IC. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
------------------------------------------------- Q46 CHECK FOR CORRECT ACM OPERATION
- Disconnect all the ACM connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the ACM connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new ACM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with
the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
------------------------------------------------- Q47 CHECK FOR CORRECT HVAC MODULE OPERATION
- Disconnect all the HVAC module connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the HVAC module connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new HVAC module. CONNECT all modules. CLEAR the DTCs. REPEAT the network
test with the scan tool.
No
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2921
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
------------------------------------------------- Q48 CHECK FOR CORRECT RETM OPERATION
- Disconnect the RETM connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the RETM connector and make sure it seats correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new RETM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with
the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
------------------------------------------------- Q49 CHECK FOR CORRECT DSM OPERATION
- Disconnect all the DSM connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the DSM connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new DSM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with
the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
------------------------------------------------- Q50 CHECK FOR CORRECT SDARS MODULE
OPERATION
- Disconnect the SDARS module connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the SDARS module connector and make sure it seats correctly.
- Operate the system and verify the concern is still present.
Is the concern still present?
Yes
INSTALL a new SDARS module. CONNECT all modules. CLEAR the DTCs. REPEAT the network
test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2922
------------------------------------------------- Q51 CHECK FOR CORRECT PRB MODULE OPERATION
- Disconnect all the PRB module connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the PRB module connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new PRB module. CONNECT all modules. CLEAR the DTCs. REPEAT the network
test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
------------------------------------------------- Q52 CHECK FOR CORRECT PAM OPERATION
- Disconnect the PAM connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the PAM connector and make sure it seats correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new PAM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with
the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
------------------------------------------------- Q53 CHECK FOR CORRECT APIM OPERATION
- Disconnect the APIM connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the APIM connector and make sure it seats correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new APIM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with
the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
------------------------------------------------- Q54 CHECK FOR CORRECT SJB OPERATION
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2923
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new SJB. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with
the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
------------------------------------------------Pinpoint Test R: Intermittent No Medium Speed Controller Area Network (MS-CAN)
Communication, One Or More Modules Are Not Respo
Communications Network
Pinpoint Tests
Pinpoint Test R: 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 Medium Speed Controller Area
Network (MS-CAN). The MS-CAN is used for communication between the following modules:
- Accessory Protocol Interface Module (APIM)
- Audio Control Module (ACM)
- Driver Seat Module (DSM)
- HVAC module
- Instrument Cluster (IC)
- Parking Aid Module (PAM)
- Power Running Board (PRB) module
- Rear Entertainment Module (RETM)
- Satellite Digital Audio Receiver System (SDARS) module
- Smart Junction Box (SJB)
In the event that 1 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
PINPOINT TEST R: INTERMITTENT NO MS-CAN COMMUNICATION, ONE OR MORE
MODULES ARE NOT RESPONDING DURING NETWORK TEST
NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection
and verification before proceeding with the pinpoint test. See: Initial Inspection and Diagnostic
Overview/Communications Network/Inspection And Verification
NOTE: Various network DTCs will set while disabling modules in this test procedure which will
need to be cleared after the diagnostic procedure is completed.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
-------------------------------------------------
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2924
R1 CHECK THE DLC PINS FOR DAMAGE
- Ignition OFF.
- Disconnect the scan tool cable from the DLC.
- Inspect DLC pins 3 and 11 for damage.
- Are DLC pins 3 and 11 OK?
Yes
GO to R2.
No
REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- R2 CHECK THE MS-CAN TERMINATION RESISTANCE
- Disconnect: Negative Battery Cable.
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the
DLC C251-11, circuit VDB07 (VT/OG), harness side.
- Is the resistance between 54 and 66 ohms?
Yes
GO to R3.
No
CONNECT the negative battery cable. Go To Pinpoint Test P. See: Pinpoint Test P: The Accessory
Protocol Interface Module (APIM) Does Not Respond To The Scan Tool
------------------------------------------------- R3 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND
- Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and
ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to R4.
No
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2925
CONNECT the negative battery cable. Go To Pinpoint Test P. See: Pinpoint Test P: The Accessory
Protocol Interface Module (APIM) Does Not Respond To The Scan Tool
------------------------------------------------- R4 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS
FOR A SHORT TO VOLTAGE
- Ignition ON.
- Measure the voltage between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground;
and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground.
- Are the voltages greater than 6 volts?
Yes
REPAIR the circuit in question. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
GO to R5.
------------------------------------------------- R5 CHECK FOR RESTORED NETWORK
COMMUNICATION WITH THE HVAC MODULE DISABLED
- Disconnect: SJB Fuses 20 (10A) and 28 (10A).
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
- Do all other modules pass the network test?
Yes
INSTALL the removed fuses. Go To Pinpoint Test I. See: Pinpoint Test I: The HVAC Module Does
Not Respond To The Scan Tool
No
INSTALL the removed fuses. GO to R6.
------------------------------------------------- R6 CHECK FOR RESTORED NETWORK
COMMUNICATION WITH THE ACM DISABLED
- Disconnect: SJB Fuse 3 (20A) and 12 (5A).
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
- Do all other modules pass the network test?
Yes
INSTALL the removed fuses. Go To Pinpoint Test J. See: Pinpoint Test J: The Audio Control
Module (ACM) Does Not Respond To The Scan Tool
No
INSTALL the removed fuses. GO to R7.
------------------------------------------------- R7 VERIFY VEHICLE EQUIPMENT - DSM
- Inspect the vehicle for a DSM.
- Is the vehicle equipped with a DSM?
Yes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2926
GO to R8.
No
GO to R9.
------------------------------------------------- R8 CHECK FOR RESTORED NETWORK
COMMUNICATION WITH THE DSM DISABLED
- Disconnect: SJB Fuse 1 (20A).
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
- Do all other modules pass the network test?
Yes
INSTALL the removed fuse. Go To Pinpoint Test M. See: Pinpoint Test M: The Driver Seat Module
(DSM) Does Not Respond To The Scan Tool
No
INSTALL the removed fuse. GO to R9.
------------------------------------------------- R9 VERIFY VEHICLE EQUIPMENT - PRB MODULE
- Inspect the vehicle for power running boards.
- Is the vehicle equipped with power running boards?
Yes
GO to R10.
No
GO to R11.
------------------------------------------------- R10 CHECK FOR RESTORED NETWORK
COMMUNICATION WITH THE PRB MODULE DISABLED
- Disconnect: BJB Fuse 19 (30A).
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
- Do all other modules pass the network test?
Yes
INSTALL the removed fuse. Go To Pinpoint Test N. See: Pinpoint Test N: The Power Running
Board Module Does Not Respond To The Scan Tool
No
INSTALL the removed fuse. GO to R11.
------------------------------------------------- R11 VERIFY VEHICLE EQUIPMENT - RETM APIM AND/OR
SDARS MODULE
- Inspect the vehicle for an RETM, an APIM, and/or a SDARS module.
- Is the vehicle equipped with an RETM, an APIM and/or a SDARS module?
Yes
GO to R12.
No
GO to R14.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2927
------------------------------------------------- R12 CHECK FOR RESTORED NETWORK
COMMUNICATION WITH THE RETM, APIM, AND/OR SDARS MODULE DISABLED
NOTE: When re-running the network test, the network test application must be first closed or the
screen display will revert back to the prior run network test results.
- Disconnect: BJB Fuse 41 (15A).
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
- Do all other modules pass the network test?
Yes
INSTALL the removed fuse. For vehicles equipped with two or more of the following modules:
RETM, APIM, SDARS module, GO to R13.
For vehicles equipped with a RETM only, Go To Pinpoint Test L. See: Pinpoint Test L: The Rear
Entertainment Module (RETM) Does Not Respond To The Scan Tool
For vehicles equipped with a APIM only, Go To Pinpoint Test P. See: Pinpoint Test P: The
Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool
For vehicles equipped with a SDARS module only, Go To Pinpoint Test K. See: Pinpoint Test K:
The Satellite Digital Audio Receiver System (SDARS) Module Does Not Respond To The Scan
Tool
No
INSTALL the removed fuse. GO to R16.
------------------------------------------------- R13 VERIFY VEHICLE EQUIPMENT - RETM
- Inspect the vehicle for an RETM.
- Is the vehicle equipped with an RETM?
Yes
GO to R14.
No
GO to R15.
------------------------------------------------- R14 CHECK FOR RESTORED NETWORK
COMMUNICATION WITH THE RETM DISCONNECTED
NOTE: When re-running the network test, the network test application must be first closed or the
screen display will revert back to the prior run network test results.
- Disconnect: RETM C9029.
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
- Do all other modules pass the network test?
Yes
CONNECT the RETM. Go To Pinpoint Test L. See: Pinpoint Test L: The Rear Entertainment
Module (RETM) Does Not Respond To The Scan Tool
No
GO to R15
------------------------------------------------- R15 CHECK FOR RESTORED NETWORK
COMMUNICATION WITH THE APIM DISCONNECTED
NOTE: When re-running the network test, the network test application must be first closed or the
screen display will revert back to the prior run network
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2928
test results.
- Disconnect: APIM C3342.
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
Do all other modules pass the network test?
Yes
CONNECT the APIM. Go To Pinpoint Test P. See: Pinpoint Test P: The Accessory Protocol
Interface Module (APIM) Does Not Respond To The Scan Tool
No
CONNECT the APIM. Go To Pinpoint Test K. See: Pinpoint Test K: The Satellite Digital Audio
Receiver System (SDARS) Module Does Not Respond To The Scan Tool
------------------------------------------------- R16 VERIFY VEHICLE EQUIPMENT - PAM
- Inspect the vehicle for a PAM.
- Is the vehicle equipped with a PAM?
Yes
GO to R17.
No
GO to R18.
------------------------------------------------- R17 CHECK FOR RESTORED NETWORK
COMMUNICATION WITH THE PAM DISABLED
- Disconnect: SJB Fuse 18 (10A).
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
- Do all other modules pass the network test?
Yes
INSTALL the removed fuse. Go To Pinpoint Test O. See: Pinpoint Test O: The Parking Aid Module
(PAM) Does Not Respond To The Scan Tool
No
INSTALL the removed fuse. GO to R18.
------------------------------------------------- R18 CHECK FOR RESTORED NETWORK
COMMUNICATION WITH THE IC DISABLED
NOTE: When re-running the network test, the network test application must be first closed or the
screen display will revert back to the prior run network test results.
- Disconnect: SJB Fuse 8 (15A) and 24 (10A).
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
- Do all other modules pass the network test?
Yes
INSTALL the removed fuses. Go To Pinpoint Test G. See: Pinpoint Test G: The Instrument Cluster
(IC) Does Not Respond To The Scan Tool
No
INSTALL the removed fuses. An intermittent fault is not present. Go To Pinpoint Test Q. See:
Pinpoint Test Q: No Medium Speed Controller Area Network (MS-CAN) Communication, All
Modules Are Not Responding
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2929
------------------------------------------------Pinpoint Test S: No High Speed Controller Area Network (HS-CAN) Communication, All Modules
Are Not Responding
Communications Network
Pinpoint Tests
Pinpoint Test S: No High Speed Controller Area Network (HS-CAN) Communication, All Modules
Are Not Responding
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Normal Operation
The High Speed Controller Area Network (HS-CAN) uses an unshielded twisted pair cable, circuits
VDB04 (WH/BU) and VDB05 (WH).
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- 4X4 control module (if equipped)
- ABS module
- Accessory Protocol Interface Module (APIM) (if equipped)
- Instrument Cluster (IC)
- Occupant Classification System Module (OCSM)
- PCM
- Restraints Control Module (RCM)
- Transmission Control Module (TCM) (if equipped)
PINPOINT TEST S: NO HS-CAN COMMUNICATION, ALL MODULES ARE NOT RESPONDING
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection
and verification before proceeding with the pinpoint test. See: Initial Inspection and Diagnostic
Overview/Communications Network/Inspection And Verification
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- S1 CHECK THE DLC PINS FOR DAMAGE
- Ignition OFF.
- Disconnect the scan tool cable from the Data Link Connector (DLC).
- Inspect DLC pins 6 and 14 for damage.
- Are DLC pins 6 and 14 OK?
Yes
GO to S2.
No
REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- S2 CHECK THE HS-CAN TERMINATION RESISTANCE
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2930
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
- Is the resistance between 54 and 66 ohms?
Yes
GO to S3.
No
GO to S5.
------------------------------------------------- S3 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and
ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
GO to S4.
No
GO to S19.
------------------------------------------------- S4 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TO VOLTAGE
- Connect: Negative Battery Cable.
- Ignition ON.
- Measure the voltage between the DLC C251-6, circuit VDB04 (WH/BU), harness side and
ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground.
- Are the voltages greater than 6 volts?
Yes
REPAIR the circuit in question. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2931
The CAN has tested within specifications. Go To Pinpoint Test T to diagnose an intermittent
HS-CAN fault. See: Pinpoint Test T: Intermittent No High Speed Controller Area Network
(HS-CAN) Communication, One Or More Modules Are Not Respond
------------------------------------------------- S5 CHECK THE HS-CAN TERMINATION RESISTOR
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
- Is the resistance between 108 and 132 ohms?
Yes
GO to S6.
No
GO to S9.
------------------------------------------------- S6 CHECK THE HS-CAN TERMINATION RESISTOR WITH
THE PCM DISCONNECTED
- Disconnect: PCM C175b.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
Is the resistance between 108 and 132 ohms?
Yes
GO to S7.
No
GO to S8.
------------------------------------------------- S7 CHECK THE HS-CAN CIRCUITS BETWEEN THE PCM
AND THE DLC FOR AN OPEN
- Measure the resistance between the PCM C175b-11, circuit VDB04 (WH/BU), harness side and
the DLC C251-6, circuit VDB04 (WH/BU), harness side.
- Measure the resistance between the PCM C175b-23, circuit VDB05 (WH), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2932
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to S27.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- S8 CHECK THE HS-CAN CIRCUITS BETWEEN THE IC
AND THE DLC FOR AN OPEN
- Measure the resistance between the IC C220-7, circuit VDB04 (WH/BU), harness side and the
DLC C251-6, circuit VDB04 (WH/BU), harness side.
- Measure the resistance between the IC C220-8, circuit VDB05 (WH), harness side and the DLC
C251-14, circuit VDB05 (WH), harness side.
Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to S34.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- S9 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
- Is the resistance less than 5 ohms?
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2933
Yes
GO to S11.
No
GO to S10.
------------------------------------------------- S10 CHECK THE HS-CAN CIRCUITS FOR AN OPEN AT
THE DLC
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
- Is the resistance greater than 10,000 ohms?
Yes
REPAIR the DLC or REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR
the DTCs. REPEAT the network test with the scan tool.
No
A capacitor internal to a module may still be draining causing irregular resistance readings. WAIT 5
minutes. REPEAT the pinpoint test.
------------------------------------------------- S11 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE PCM DISCONNECTED
- Disconnect: PCM C175b.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to S12.
No
CONNECT the negative battery cable. GO to S27.
------------------------------------------------- S12 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE ABS MODULE DISCONNECTED
- Disconnect: ABS Module C155.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2934
- Is the resistance less than 5 ohms?
Yes
If the vehicle is equipped with a 4X4 control module, GO to S13.
If the vehicle is not equipped with a 4X4 control module, GO to S14.
No
CONNECT the negative battery cable. GO to S28.
------------------------------------------------- S13 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE 4X4 CONTROL MODULE DISCONNECTED
- Disconnect: 4X4 Control Module C281a.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to S14.
No
CONNECT the negative battery cable. GO to S29.
------------------------------------------------- S14 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE OCSM DISCONNECTED
- Disconnect: OCSM C3159.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
- Is the resistance less than 5 ohms?
Yes
If the vehicle is equipped with an APIM, GO to S15.
If the vehicle is not equipped with an APIM, GO to S16.
No
CONNECT the negative battery cable. GO to S30.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2935
------------------------------------------------- S15 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE APIM DISCONNECTED
- Disconnect: APIM C3342.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to S16.
No
CONNECT the negative battery cable. GO to S31.
------------------------------------------------- S16 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE RCM DISCONNECTED
- Disconnect: RCM C310b.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
- Is the resistance less than 5 ohms?
Yes
If the vehicle is equipped with a Transmission Control Module (TCM), GO to S17.
If the vehicle is not equipped with a TCM, GO to S18.
No
CONNECT the negative battery cable. GO to S32.
------------------------------------------------- S17 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE TCM DISCONNECTED
- Disconnect: TCM C1575.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
- Is the resistance less than 5 ohms?
Yes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2936
GO to S18.
No
CONNECT the negative battery cable. GO to S33.
------------------------------------------------- S18 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TOGETHER WITH THE IC DISCONNECTED
- Disconnect: IC C220.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
- Is the resistance less than 5 ohms?
Yes
REPAIR the circuits. CONNECT all modules. CONNECT the negative battery cable. CLEAR the
DTCs. REPEAT the network test with the scan tool.
No
CONNECT the negative battery cable. GO to S34.
------------------------------------------------- S19 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE PCM DISCONNECTED
- Disconnect: PCM C175b.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and
ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to S27.
No
GO to S20.
------------------------------------------------- S20 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE ABS MODULE DISCONNECTED
- Disconnect: ABS C155.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and
ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2937
Yes
CONNECT the negative battery cable. GO to S28.
No
If the vehicle is equipped with a 4X4 control module, GO to S21.
If the vehicle is not equipped with a 4X4 control module, GO to S22.
------------------------------------------------- S21 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE 4X4 CONTROL MODULE DISCONNECTED
- Disconnect: 4X4 Control Module C281a.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and
ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to S29.
No
GO to S22.
------------------------------------------------- S22 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE OCSM DISCONNECTED
- Disconnect: OCSM C3159.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and
ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground.
Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to S30.
No
If the vehicle is equipped with an APIM, GO to S23.
If the vehicle is not equipped with an APIM, GO to S24.
------------------------------------------------- S23 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE APIM DISCONNECTED
- Disconnect: APIM C3342.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and
ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2938
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to S31.
No
GO to S24.
------------------------------------------------- S24 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE RCM DISCONNECTED
- Disconnect: RCM C310b.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and
ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to S32.
No
If the vehicle is equipped with a Transmission Control Module (TCM), GO to S25.
If the vehicle is not equipped with a TCM, GO to S26.
------------------------------------------------- S25 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND WITH THE TCM DISCONNECTED
- Disconnect: TCM C1575.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and
ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to S33.
No
GO to S26.
-------------------------------------------------
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2939
S26 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH
THE IC DISCONNECTED
- Disconnect: IC C220.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and
ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to S34.
No
REPAIR the circuit in question. CONNECT all modules. CONNECT the negative battery cable.
CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- S27 CHECK FOR CORRECT PCM OPERATION
- Disconnect all the PCM connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the PCM connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new PCM. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- S28 CHECK FOR CORRECT ABS MODULE OPERATION
- Disconnect the ABS module connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the ABS module connector and make sure it seats correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new ABS module. CONNECT all modules. CLEAR the DTCs. REPEAT the network
test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
-------------------------------------------------
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2940
S29 CHECK FOR CORRECT 4X4 CONTROL MODULE OPERATION
- Disconnect the 4X4 control module connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the 4X4 control module connector and make sure it seats correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new 4X4 control module. CONNECT all modules. CLEAR the DTCs. REPEAT the
network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
------------------------------------------------- S30 CHECK FOR CORRECT OCSM OPERATION
- Disconnect the OCSM connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the OCSM connector and make sure it seats correctly.
- Verify the concern is still present.
Is the concern still present?
Yes
INSTALL a new OCSM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with
the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
------------------------------------------------- S31 CHECK FOR CORRECT APIM OPERATION
- Disconnect the APIM connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the APIM connector and make sure it seats correctly.
- Verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new APIM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with
the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
------------------------------------------------- S32 CHECK FOR CORRECT RCM OPERATION
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2941
- Disconnect all the RCM connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the RCM connectors and make sure they seat correctly.
- Verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new RCM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with
the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. REPEAT the network test with the scan tool.
------------------------------------------------- S33 CHECK FOR CORRECT TCM OPERATION
- Disconnect the TCM connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the TCM connector and make sure it seats correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new TCM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with
the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
------------------------------------------------- S34 CHECK FOR CORRECT IC OPERATION
- Disconnect the IC connector.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect the IC connector and make sure it seats correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new IC. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
------------------------------------------------Pinpoint Test T: Intermittent No High Speed Controller Area Network (HS-CAN) Communication,
One Or More Modules Are Not Respond
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2942
Communications Network
Pinpoint Tests
Pinpoint Test T: 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:
- 4X4 control module (if equipped)
- ABS module
- Accessory Protocol Interface Module (APIM) (if equipped)
- Instrument Cluster (IC)
- Occupant Classification System Module (OCSM)
- PCM
- Restraints Control Module (RCM)
- Transmission Control Module (TCM) (6R60 transmission only)
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
PINPOINT TEST T: INTERMITTENT NO HS-CAN COMMUNICATION, ONE OR MORE
MODULES ARE NOT RESPONDING DURING NETWORK TEST
NOTE: Various modules will set network DTCs during this test procedure. Clear DTCs from all
modules after the diagnostic procedure is completed.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- T1 CHECK THE DLC PINS FOR DAMAGE
- Ignition OFF.
- Disconnect the scan tool cable from the DLC.
- Inspect DLC pins 6 and 14 for damage.
- Are DLC pins 6 and 14 OK?
Yes
GO to T2.
No
REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- T2 CHECK THE HS-CAN TERMINATION RESISTANCE
- Disconnect: Negative Battery Cable.
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the
DLC C251-14, circuit VDB05 (WH), harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2943
- Is the resistance between 54 and 66 ohms?
Yes
GO to T3.
No
CONNECT the negative battery cable. Go To Pinpoint Test R. See: Pinpoint Test R: Intermittent
No Medium Speed Controller Area Network (MS-CAN) Communication, One Or More Modules Are
Not Respo
------------------------------------------------- T3 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TO GROUND
- Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and
ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to T4.
No
CONNECT the negative battery cable. Go To Pinpoint Test R. See: Pinpoint Test R: Intermittent
No Medium Speed Controller Area Network (MS-CAN) Communication, One Or More Modules Are
Not Respo
------------------------------------------------- T4 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
FOR A SHORT TO VOLTAGE
- Ignition ON.
- Measure the voltage between the DLC C251-6, circuit VDB04 (WH/BU), harness side and
ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground.
Are the voltages greater than 6 volts?
Yes
REPAIR the circuit in question. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
GO to T5.
------------------------------------------------- T5 CHECK FOR RESTORED COMMUNICATION WITH THE
PCM DISABLED
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2944
NOTE: A scan tool session must be established prior to disabling the PCM in this test step. If the
PCM has failed communication during multiple attempts to identify the vehicle, first identify the
vehicle manually by entering a PCM part number, calibration number or tear tag when prompted by
the IDS.
NOTE: When a vehicle is manually identified by a PCM part number, calibration number or tear
tag, the IDS will not automatically run a network test. The network test must be manually selected
and run.
- Disconnect: BJB Fuse 24 (10A) and 39 (15A).
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
- Do all other modules pass the network test?
Yes
INSTALL the removed fuses. Go To Pinpoint Test A. See: Pinpoint Test A: The PCM Does Not
Respond To The Scan Tool
No
INSTALL the removed fuses. GO to T6.
------------------------------------------------- T6 CHECK FOR RESTORED NETWORK
COMMUNICATION WITH THE ABS MODULE AND 4X4 CONTROL MODULE (IF EQUIPPED)
DISABLED
NOTE: When re-running the network test, the network test application must be first closed or the
screen display will revert back to the prior run network test results.
- Disconnect: SJB fuse 18 (10A).
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
- Do all other modules pass the network test?
Yes
INSTALL the removed fuse. If the vehicle is equipped with a 4X4 control module, GO to T7. If the
vehicle is not equipped with a 4X4 control module, Go To Pinpoint Test C. See: Pinpoint Test C:
The ABS Module Does Not Respond To The Scan Tool
No
INSTALL the removed fuse. GO to T8.
------------------------------------------------- T7 CHECK FOR RESTORED NETWORK
COMMUNICATION WITH THE ABS MODULE DISCONNECTED
NOTE: When re-running the network test, the network test application must be first closed or the
screen display will revert back to the prior run network test results.
- Disconnect: ABS Module C155.
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
- Do all other modules pass the network test?
Yes
CONNECT the ABS module. Go To Pinpoint Test C. See: Pinpoint Test C: The ABS Module Does
Not Respond To The Scan Tool
No
CONNECT the ABS module. Go To Pinpoint Test E. See: Pinpoint Test E: The 4X4 Control Module
Does Not Respond To The Scan Tool
------------------------------------------------- T8 CHECK FOR RESTORED NETWORK
COMMUNICATION WITH THE RCM AND OCSM DISABLED
NOTE: When re-running the network test, the network test application must be first closed or the
screen display will revert back to the prior run network test results.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2945
- Disconnect: SJB Fuse 17 (10A).
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
- Do all other modules pass the network test?
Yes
INSTALL the removed fuse. GO to T9.
No
INSTALL the removed fuse. GO to T10.
------------------------------------------------- T9 CHECK FOR RESTORED NETWORK
COMMUNICATION WITH THE RCM DISCONNECTED
NOTE: When re-running the network test, the network test application must be first closed or the
screen display will revert back to the prior run network test results.
- Disconnect: RCM C310b.
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
- Do all other modules pass the network test?
Yes
CONNECT the RCM. Go To Pinpoint Test D. See: Pinpoint Test D: The Restraints Control Module
(RCM) Does Not Respond To The Scan Tool
No
CONNECT the RCM. Go To Pinpoint Test F. See: Pinpoint Test F: The Occupant Classification
System Module (OCSM) Does Not Respond To The Scan Tool
------------------------------------------------- T10 VERIFY VEHICLE EQUIPMENT - TCM
- A TCM is present in 6R60 transmission equipped vehicles only. Inspect the vehicle for a 6R60
transmission.
- Is the vehicle equipped with a 6R60 transmission?
Yes
GO to T11.
No
GO to T12.
------------------------------------------------- T11 CHECK FOR RESTORED NETWORK
COMMUNICATION WITH THE TCM DISABLED
NOTE: When re-running the network test, the network test application must be first closed or the
screen display will revert back to the prior run network test results.
- Disconnect: BJB Fuse 27 (20A) and SJB Fuse 9 (2A).
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
- Do all other modules pass the network test?
Yes
INSTALL the removed fuses. Go To Pinpoint Test B. See: Pinpoint Test B: The Transmission
Control Module (TCM) Does Not Respond To The Scan Tool
No
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2946
INSTALL the removed fuses. GO to T12.
------------------------------------------------- T12 VERIFY VEHICLE EQUIPMENT - APIM
- Inspect the vehicle for an APIM.
- Is the vehicle equipped with an APIM?
Yes
GO to T13.
No
GO to T14.
------------------------------------------------- T13 CHECK FOR RESTORED NETWORK
COMMUNICATION WITH THE APIM DISABLED
NOTE: When re-running the network test, the network test application must be first closed or the
screen display will revert back to the prior run network test results.
- Disconnect: BJB Fuse 41 (15A).
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
- Do all other modules pass the network test?
Yes
INSTALL the removed fuse. Go To Pinpoint Test P. See: Pinpoint Test P: The Accessory Protocol
Interface Module (APIM) Does Not Respond To The Scan Tool
No
INSTALL the removed fuse. GO to T14.
------------------------------------------------- T14 CHECK FOR RESTORED NETWORK
COMMUNICATION WITH THE IC DISABLED
NOTE: When re-running the network test, the network test application must be first closed or the
screen display will revert back to the prior run network test results.
- Disconnect: SJB Fuses 8 (15A) and 24 (10A).
- Enter the following diagnostic mode on the scan tool: Network Test.
- Repeat the network test.
- Do all other modules pass the network test?
Yes
INSTALL the removed fuses. Go To Pinpoint Test G. See: Pinpoint Test G: The Instrument Cluster
(IC) Does Not Respond To The Scan Tool
No
INSTALL the removed fuses. An intermittent fault is not present. Go To Pinpoint Test S. See:
Pinpoint Test S: No High Speed Controller Area Network (HS-CAN) Communication, All Modules
Are Not Responding
------------------------------------------------Pinpoint Test U: No Power To The Scan Tool
Communications Network
Pinpoint Tests
Pinpoint Test U: No Power To The Scan Tool
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2947
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
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).
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
- DLC
- Scan tool
PINPOINT TEST U: NO POWER TO THE SCAN TOOL
NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection
and verification before proceeding with the pinpoint test. See: Initial Inspection and Diagnostic
Overview/Communications Network/Inspection And Verification
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- U1 CHECK THE DLC PINS FOR DAMAGE
- Disconnect the scan tool cable from the DLC.
- Inspect DLC pins 4, 5 and 16 for damage.
- Are DLC pins 4, 5 and 16 OK?
Yes
GO to U2.
No
REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- U2 CHECK THE DLC VOLTAGE SUPPLY CIRCUIT FOR AN
OPEN
- Measure the voltage between the DLC C251-16, circuit SBP04 (GN/RD), harness side and
ground.
- Is the voltage greater than 10 volts?
Yes
GO to U3.
No
VERIFY the Smart Junction Box (SJB) fuse 4 (10A) is OK. If OK, REPAIR the circuit. If not OK,
REFER to the Wiring Diagrams to identify the
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2948
possible causes of the circuit short. REPEAT the network test with the scan tool.
------------------------------------------------- U3 CHECK THE DLC GROUND CIRCUITS FOR AN OPEN
- Disconnect: Negative Battery Cable.
- Measure the resistance between the DLC C251-5, circuit GD138 (BK/WH), harness side and
ground; and between the DLC C251-4, circuit GD138 (BK/WH), harness side and ground.
- Are the resistances less than 5 ohms?
Yes
REPAIR the scan tool. CONNECT the negative battery cable. REPEAT the network test with the
scan tool.
No
REPAIR the circuit in question. CONNECT the negative battery cable. REPEAT the network test
with the scan tool.
-------------------------------------------------
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2949
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2950
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Page 2951
Information Bus: Service and Repair
PROGRAMMABLE MODULE INSTALLATION
Special Tool(s)
Special Tool(s)
Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The
Original Module Is Available
NOTE: Following module installation, some modules require a separate learning procedure be
carried out. For instructions, refer to the specific module removal and installation procedures.
1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module
Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the
module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF
position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow
the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8.
The IDS downloads the data into the new module and displays Module Configuration Complete. 9.
Test module for correct operation.
Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The
Original Module Is Not Available
NOTE: Following module installation, some modules require a separate learning procedure be
carried out. For adaptive learning and calibration instructions, refer to the specific module removal
and installation procedures.
1. Install the new module. 2. Connect the IDS and identify the vehicle as normal. 3. From the
Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable
Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions,
turn the ignition key to the OFF position, and press the check mark. 7. Follow the on-screen
instructions, turn the ignition key to the ON position, and press the check mark. 8. If the data is not
available, the IDS displays a screen stating to contact the As-Built Data Center. Retrieve the data
from the technician service
publication website at this time and press the check mark.
9. Enter the module data and press the check mark.
10. The IDS downloads the data into the new module and displays Module Configuration
Complete. 11. Test module for correct operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations
Knock Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations > Page 2955
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Locations > Page 2956
Knock Sensor: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations > Page 2957
Knock Sensor: Description and Operation
Engine Control Components
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.
Two Types of Knock Sensor (KS)
Two Types of Knock Sensor (KS)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations > Page 2958
Knock Sensor: Service and Repair
Knock Sensor (KS) - 4.0L SOHC
Removal and Installation
1. Remove the intake manifold.
2. Disconnect the Knock Sensor (KS) electrical connector.
3. Remove the bolt and the KS.
- To install, tighten to 20 Nm (177 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 2962
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 2963
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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)
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 four 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 three
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/No Diagnostic Trouble Codes (DTCs) Present Symptom Chart Index.
- 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 ignition in the RUN position (engine not running) if
DTC P1000 is set.
CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
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.
Typical Manifold Absolute Pressure (MAP) Sensor
Typical Manifold Absolute Pressure (MAP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM
> Component Information > Description and Operation
Oil Temperature Sensor For ECM: Description and Operation
Engine Control Components
Engine Oil Temperature (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.
Typical Thread Type Sensor
Typical EOT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2977
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2978
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2979
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2980
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #21
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2981
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2982
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2983
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2984
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2985
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Heated Oxygen Sensor (HO2S) #22
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2988
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2989
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2990
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Description and Operation > Heated Oxygen Sensor (HO2S)
Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S)
Engine Control Components
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.
Typical Heated Oxygen Sensor (HO2S)
Typical Heated Oxygen Sensor (HO2S)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Description and Operation > Heated Oxygen Sensor (HO2S) > Page 2993
Oxygen Sensor: Description and Operation Universal Heated Oxygen Sensor (HO2S)
Engine Control Components
Universal Heated Oxygen Sensor (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 HO2S 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor Exploded View
Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page
2996
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S)
Heated Oxygen Sensor (HO2S)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If the RH Heated Oxygen Sensor (HO2S) is being serviced, remove the 2 bolts and position the
heat shield aside.
3. Disconnect the HO2S electrical connector.
4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal.
Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S.
Installation
1. Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S.
2. Using the Exhaust Gas Oxygen Sensor Socket, install the HO2S.
- Calculate the correct torque wrench setting for the following torque.
- Using the Exhaust Gas Oxygen Sensor Socket, tighten to 41 Nm (30 lb-ft).
3. Connect the HO2S electrical connector.
4. If the RH HO2S is being serviced, position the heat shield and install the 2 bolts.
- Tighten to 20 Nm (177 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page
2997
Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
Catalyst Monitor Sensor
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If the RH Catalyst Monitor Sensor (CMS) is being serviced, remove the 2 bolts and position the
heat shield aside.
3. Disconnect the CMS electrical connector.
4. NOTE: If necessary, lubricate the CMS with penetrating and lock lubricant to ease removal.
Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS.
Installation
1. Apply a light coat of anti-seize lubricant to the threads of the CMS.
2. Using the Exhaust Gas Oxygen Sensor Socket, install the CMS.
- Calculate the correct torque wrench setting for the following torque.
- Using the Exhaust Gas Oxygen Sensor Socket, tighten to 41 Nm (30 lb-ft).
3. Connect the CMS electrical connector.
4. If the RH CMS is being serviced, position the heat shield and install the 2 bolts.
- Tighten to 20 Nm (177 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch >
Component Information > Locations > Page 3001
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch >
Component Information > Description and Operation > Power Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
Engine Control Components
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 EPC
pressure during increased engine load, for example during parking maneuvers.
Typical Power Steering Pressure (PSP) Switch
Typical Power Steering Pressure (PSP) Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch >
Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 3004
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
Engine Control Components
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 EPC pressure during increased engine load, for example, during
parking maneuvers.
Typical Power Steering Pressure (PSP) Sensor
Typical Power Steering Pressure (PSP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
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
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
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.
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components Exploded View
Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System
Components - Exploded View
Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components Exploded View > Page 3010
Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System
Module
Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC
Removal and Installation
1. Disconnect the EGR system module electrical and vacuum connectors.
2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting.
- To install, tighten to 40 Nm (30 lb-ft).
3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle
facing the intake manifold.
Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket.
- To install, tighten to 25 Nm (18 lb-ft).
4. NOTE: The EGR system module sealing surfaces are soft metals.
Carefully clean the EGR system module sealing surfaces.
5. To install, reverse the removal procedure.
- Install a new EGR system module gasket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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), which delivers 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 torque-based 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 two 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. 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 one reference voltage and one signal return circuit between the PCM and the ETB. The
reference voltage and the signal return circuits are shared with the reference voltage and signal
return circuits used by the accelerator pedal position (APP) sensor. There are also two throttle
position (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. For additional
information on the APP sensor, refer to Engine Control Components See: Description and
Operation/Engine Control Components.
Electronic Throttle Control (ETC) System Strategy
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)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
3015
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 two 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.
ETC System With A 3-Track APP Sensor Failure Mode And Effects Management:
a - ETC illuminates or displays a message on the message center immediately; MIL illuminates
after 2 driving cycles
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
3016
ETC System With A 2-Track APP Sensor Failure Mode And Effects Management:
Electronic Throttle Monitor Operation:
a - Monitor execution is continuous. Monitor false detection duration is less than 1 second to
register a concern.
APP and TP Sensor Inputs
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
3017
Accelerator Pedal Position (APP) Sensor Check:
Correlation and range/performance - sensor disagreement between processors internal to the
PCM. Monitor execution is continuous. Monitor false detection duration is less than 1 second to
register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions for additional
DTC information.
Throttle Position (TP) Sensor Check:
a - Correlation and range/performance - sensor disagreement between processors internal to the
PCM, TP inconsistent with requested throttle plate position. Monitor execution is continuous.
Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic
Trouble Code (DTC) Charts and Descriptions for additional DTC information.
Electronic Throttle Actuator Control (TAC) Output
Electronic TAC Operation Check:
a - Note: For all DTCs, in addition to the MIL, the powertrain malfunction indicator (wrench) is on for
the concern that caused the FMEM action. Monitor execution is continuous. Monitor false detection
duration is less than 5 seconds to register a concern.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
Engine Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3026
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3027
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
> Page 3033
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
> Page 3034
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3035
Engine Control Module: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3036
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3037
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3038
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3039
Engine Control Module: Diagrams
C175B Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3040
C175B Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3041
C175E Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3042
C175E Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3043
C175E Part 3
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3044
C175T Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3045
C175T Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 DTC P1635 or
P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware
or parameter changes made to the vehicle since production. Failure to carry out this procedure
properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle
ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID
Block and also under Making Changes to the PCM Calibration. The VID block contains many items
used by the strategy for a variety of functions. Some of these items include the vehicle identification
number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the
presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual
shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID
block is displayed on the scan tool.
When changing items in the VID block, the strategy places range limits on certain items such as
tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this
limit is reached, the scan tool displays a message indicating the need to flash the PCM again to
reset the VID block.
On selected vehicles equipped with permanent DTC reporting capabilities, neutral profile correction
should be learned after a PCM replacement in order to activate the misfire monitor. This can be
accomplished using the Misfire Monitor Neutral Profile Learn function on the scan tool.
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.
Neutral Profile Correction
In order for the misfire detection system to function properly, any mechanical inaccuracies in the
crankshaft position (CKP) sensor must be learned by the PCM. This information is stored in
non-volatile memory (NVM) in the PCM. It is not cleared when the keep alive memory (KAM) is
reset.
Neutral profile learning is accomplished using the scan tool any time a PCM is replaced. It should
also be relearned any time the CKP sensor is replaced or major engine repairs have been
completed.
To determine if the neutral profile learning has been completed, check the MP_LRN parameter
identification (PID) using the scan tool. The PID should read YES if the neutral profile learning has
been completed. If the PID reads NO, complete the neutral profile learning prior to diagnosing any
misfire DTCs.
Programming the VID Block for a Replacement PCM
The VID block on a replacement PCM is blank and requires programming. There are two
procedures available. The first is an automatic data transfer from the old PCM to the new PCM,
and the second is manual data entry into the new PCM.
Automatic data transfer 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 be downloaded to the new PCM after it has been installed.
Carry out manual data entry if the old PCM 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 programmed PCM 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3048
At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production, or the need to reset the VID block
because it has reached its limit. Refer to Module Reprogramming on the scan tool.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3049
Engine Control Module: Removal and Replacement
Powertrain Control Module (PCM)
A/C Tube Brackets
PCM
Removal
All vehicles
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3050
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 (PMI) procedure. See: Information Bus/Testing and
Inspection/Programming and Relearning
Vehicles equipped with a 4.6L (3V) engine
2. Remove the Air Cleaner (ACL).
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 2 bolts and the PCM.
Installation
All vehicles
1. Install the PCM and the 2 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.
- Tighten to 7 Nm (62 lb-in).
Vehicles equipped with a 4.6L (3V) engine
4. Install the ACL.
All vehicles
5. Restore the module configuration. Carry out the module configuration restore steps of the
Programmable Module Installation (PMI) procedure.
See: Information Bus/Testing and Inspection/Programming and Relearning
6. Reprogram the Passive Anti-Theft System (PATS). Carry out the Parameter Reset procedure.
See: Accessories and Optional Equipment/Antitheft
and Alarm Systems/Testing and Inspection/Programming and Relearning/Passive Anti-Theft
System (PATS) Parameter Reset
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3054
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3055
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3060
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3061
Accelerator Pedal Position Sensor: Description and Operation
Engine Control Components
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
There are two 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 two
pedal position signals make sure the PCM receives a correct input even if one 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 two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six
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 (TP) 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. For additional information, refer
to Torque Based Electronic Throttle Control (ETC) See: Electronic Throttle Control
Module/Description and Operation.
2-Track APP Sensor
Typical 2-Track APP Sensor
3-Track APP Sensor
There are three 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 three pedal position signals make sure the PCM
receives a correct input even if one 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 two reference voltage circuits, two signal
return circuits, and three signal circuits (a total of seven 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. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) See: Electronic Throttle Control Module/Description and Operation.
3-Track APP Sensor
Typical 3-Track APP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
Air Flow Meter/Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3065
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3067
Air Flow Meter/Sensor: Description and Operation
Engine Control Components
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 (TCC) 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 IAT sensor.
The hot wire electronic sensing element must be replaced as an assembly. Replacing only the
element may change the air flow calibration.
Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT
Sensor Wire Where Applicable) Terminals
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
Typical Mass Air Flow (MAF) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Typical Drop-in Mass Air Flow (MAF) Sensor
Typical Drop-in Mass Air Flow (MAF) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3069
Air Flow Meter/Sensor: Service and Repair
Mass Air Flow (MAF) Sensor - 4.0L SOHC
Removal and Installation
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the 2 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position
Sensor 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position
Sensor 1 > Page 3074
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position
Sensor 1 > Page 3075
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position
Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position
Sensor > Page 3078
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position
Sensor > Page 3079
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3080
Camshaft Position Sensor: Description and Operation
Engine Control Components
Camshaft Position (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 two CMP sensors are equipped with variable camshaft timing (VCT). The second
sensor is used to identify the position of the camshaft on bank 2.
There are two types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin
Hall-effect type sensor.
Typical Variable Reluctance CMP Sensor
Typical Variable Reluctance CMP Sensor
Typical Hall-effect CMP Sensor
Typical Hall-effect CMP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3081
Camshaft Position Sensor: Service and Repair
Camshaft Position (CMP) Sensor - 4.0L SOHC
Removal and Installation
1. Disconnect the Camshaft Position (CMP) sensor electrical connector.
2. Remove the bolt and the CMP sensor.
- To install, tighten to 6 Nm (53 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
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.
Typical Clutch Pedal Position (CPP) Switch
Typical Clutch Pedal Position (CPP) Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Page 3088
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Page 3089
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Engine Control Components
Engine Coolant Temperature (ECT) Sensor
The ECT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases, and the resistance
increases as the temperature decreases. The varying resistance changes the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor
determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage
minus the voltage drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The PCM uses the ECT input for fuel
control and for cooling fan control. There are three types of ECT sensors, threaded, push-in, and
twist-lock. The ECT sensor is located in an engine coolant passage.
Typical Thread Type Sensor
Typical Thread Type ECT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Page 3090
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature (ECT) Sensor - 4.0L SOHC
Removal and Installation
1. Drain the cooling system.
2. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
3. Remove the clip and the ECT sensor.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3095
Crankshaft Position Sensor: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3097
Crankshaft Position Sensor: Description and Operation
Engine Control Components
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.
Typical Crankshaft Position (CKP) Sensor
Typical Crankshaft Position (CKP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3098
Crankshaft Position Sensor: Service and Repair
Crankshaft Position (CKP) Sensor - 4.0L SOHC
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
3. Remove the 2 bolts and the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. NOTE: Be sure the sensor wiring is routed away from the battery cable.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3103
Engine Temperature Sensor: Description and Operation
Engine Control Components
Cylinder Head Temperature (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. For
additional information, refer to Powertrain Control Software See: Description and
Operation/Powertrain Control Software for Fail-Safe Cooling Strategy.
Typical CHT Sensor
Typical CHT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
Fuel Level Input (FLI)
The FLI is a communications network message. Most vehicle applications use a potentiometer type
FLI sensor connected to a float in the FP module to determine fuel level.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler
Pipe - Exploded View
Fuel Level Sensor: Service and Repair Fuel Tank and Filler Pipe - Exploded View
Fuel Tank and Filler Pipe - Exploded View
Explorer Sport Trac
NOTE: Vehicle body removed from art for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler
Pipe - Exploded View > Page 3109
Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Pipe - Exploded View > Page 3110
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler
Pipe - Exploded View > Page 3111
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler
Pipe - Exploded View > Page 3112
Fuel Level Sensor: Service and Repair Fuel Level Sender
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 (FP). For additional information, refer to Fuel Pump See: Fuel Delivery
and Air Induction/Fuel Pump/Service and
Repair/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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler
Pipe - Exploded View > Page 3113
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 FP body.
2. Route the fuel level sender wire through the center of the FP.
3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate.
Hook the fuel level sender on the FP 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Pipe - Exploded View > Page 3114
6. Install the fuel level sender cover and screw and tighten the screw.
7. Install the FP. For additional information, refer to Fuel Pump See: Fuel Delivery and Air
Induction/Fuel Pump/Service and Repair/Fuel Pump.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Fuel Tank Pressure Sensor: Description and Operation
Engine Control Components
Fuel Tank Pressure (FTP) Sensor
The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure.
Fuel Tank Pressure (FTP) Sensor
Fuel Tank Pressure (FTP) Sensor
In-line Fuel Tank Pressure (FTP) Sensor
In-line Fuel Tank Pressure (FTP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor
Removal and Installation
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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: 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. For additional information, refer to
Evaporative Emission Canister See: Emission Control
Systems/Evaporative Emissions System/Evaporative Emission Control Canister/Service and
Repair.
2. Remove the fuel tank shield from the fuel tank.
3. Disconnect the Fuel Tank Pressure (FTP) sensor electrical connector.
4. Disconnect the 3 FTP sensor and vapor tube assembly quick connect couplings from the Fuel
Pump (FP) module and the vapor vent valves.
5. Remove the FTP sensor and vapor tube assembly.
6. To install, reverse the removal procedure.
- Carry out the Evaporative Emission System Leak Test. For additional information, refer to
Evaporative Emission System Leak Test See: Emission Control Systems/Evaporative Emissions
System/Testing and Inspection.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3125
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3126
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3127
Intake Air Temperature Sensor: Description and Operation
Engine Control Components
Intake Air Temperature (IAT) 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 sensor provides air temperature information to the PCM. The PCM uses the air
temperature information as a correction factor in the calculation of fuel, spark, and air flow.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Currently there are two 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 two 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.
Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors
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
Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into a Drop-in or Flange-type
MAF sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3131
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3132
Knock Sensor: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3133
Knock Sensor: Description and Operation
Engine Control Components
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.
Two Types of Knock Sensor (KS)
Two Types of Knock Sensor (KS)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3134
Knock Sensor: Service and Repair
Knock Sensor (KS) - 4.0L SOHC
Removal and Installation
1. Remove the intake manifold.
2. Disconnect the Knock Sensor (KS) electrical connector.
3. Remove the bolt and the KS.
- To install, tighten to 20 Nm (177 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
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.
Typical Manifold Absolute Pressure (MAP) Sensor
Typical Manifold Absolute Pressure (MAP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation
Oil Temperature Sensor For ECM: Description and Operation
Engine Control Components
Engine Oil Temperature (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.
Typical Thread Type Sensor
Typical EOT Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S)
#11
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S)
#11 > Page 3145
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S)
#11 > Page 3146
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S)
#11 > Page 3147
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S)
#11 > Page 3148
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #21
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S)
#11 > Page 3149
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S)
#11 > Page 3150
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S)
#11 > Page 3151
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S)
#11 > Page 3152
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S)
#11 > Page 3153
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S)
#22
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S)
#22 > Page 3156
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S)
#22 > Page 3157
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S)
#22 > Page 3158
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated
Oxygen Sensor (HO2S)
Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S)
Engine Control Components
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.
Typical Heated Oxygen Sensor (HO2S)
Typical Heated Oxygen Sensor (HO2S)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated
Oxygen Sensor (HO2S) > Page 3161
Oxygen Sensor: Description and Operation Universal Heated Oxygen Sensor (HO2S)
Engine Control Components
Universal Heated Oxygen Sensor (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 HO2S 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 (V6-4.0L (2009))
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) and Catalyst Monitor Sensor - Exploded View
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor Exploded View
Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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) and Catalyst Monitor Sensor - Exploded View > Page 3164
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S)
Heated Oxygen Sensor (HO2S)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If the RH Heated Oxygen Sensor (HO2S) is being serviced, remove the 2 bolts and position the
heat shield aside.
3. Disconnect the HO2S electrical connector.
4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal.
Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S.
Installation
1. Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S.
2. Using the Exhaust Gas Oxygen Sensor Socket, install the HO2S.
- Calculate the correct torque wrench setting for the following torque.
- Using the Exhaust Gas Oxygen Sensor Socket, tighten to 41 Nm (30 lb-ft).
3. Connect the HO2S electrical connector.
4. If the RH HO2S is being serviced, position the heat shield and install the 2 bolts.
- Tighten to 20 Nm (177 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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) and Catalyst Monitor Sensor - Exploded View > Page 3165
Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
Catalyst Monitor Sensor
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If the RH Catalyst Monitor Sensor (CMS) is being serviced, remove the 2 bolts and position the
heat shield aside.
3. Disconnect the CMS electrical connector.
4. NOTE: If necessary, lubricate the CMS with penetrating and lock lubricant to ease removal.
Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS.
Installation
1. Apply a light coat of anti-seize lubricant to the threads of the CMS.
2. Using the Exhaust Gas Oxygen Sensor Socket, install the CMS.
- Calculate the correct torque wrench setting for the following torque.
- Using the Exhaust Gas Oxygen Sensor Socket, tighten to 41 Nm (30 lb-ft).
3. Connect the CMS electrical connector.
4. If the RH CMS is being serviced, position the heat shield and install the 2 bolts.
- Tighten to 20 Nm (177 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3169
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation
> Power Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
Engine Control Components
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 EPC
pressure during increased engine load, for example during parking maneuvers.
Typical Power Steering Pressure (PSP) Switch
Typical Power Steering Pressure (PSP) Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation
> Power Steering Pressure (PSP) Switch > Page 3172
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
Engine Control Components
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 EPC pressure during increased engine load, for example, during
parking maneuvers.
Typical Power Steering Pressure (PSP) Sensor
Typical Power Steering Pressure (PSP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
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
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
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.
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and
Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View
Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System
Components - Exploded View
Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and
Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View > Page 3178
Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System
Module
Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC
Removal and Installation
1. Disconnect the EGR system module electrical and vacuum connectors.
2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting.
- To install, tighten to 40 Nm (30 lb-ft).
3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle
facing the intake manifold.
Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket.
- To install, tighten to 25 Nm (18 lb-ft).
4. NOTE: The EGR system module sealing surfaces are soft metals.
Carefully clean the EGR system module sealing surfaces.
5. To install, reverse the removal procedure.
- Install a new EGR system module gasket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins >
Customer Interest for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC P2135 Set
Throttle Position Sensor: Customer Interest A/C, Engine Controls - MIL ON/DTC P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins >
Customer Interest for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC P2135 Set >
Page 3187
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC P2135
Set
Throttle Position Sensor: All Technical Service Bulletins A/C, Engine Controls - MIL ON/DTC
P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Throttle Position Sensor: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC P2135
Set > Page 3193
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page
3194
Throttle Position Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page
3195
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page
3196
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation >
Electronic Throttle Body (ETB) Throttle Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle
Position Sensor
Engine Control Components
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. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) See: Electronic Throttle Control Module/Description and Operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation >
Electronic Throttle Body (ETB) Throttle Position Sensor > Page 3199
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
Engine Control Components
Throttle Position (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, four operating conditions are determined by the
PCM from the TP. These 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
Typical TP Sensor
Typical TP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page
3200
Throttle Position Sensor: Service and Repair
Throttle Position (TP) Sensor
Removal
All vehicles
1. Remove the Air Cleaner (ACL) outlet pipe.
2. Disconnect the Throttle Position (TP) sensor electrical connector.
Vehicles equipped with a 4.6L (3V) engine
3. Disconnect the PCV hose from the heated PCV fitting.
4. Disconnect the heated PCV fitting electrical connector.
5. Remove the 2 bolts and the heated PCV fitting.
- Remove and discard the heated PCV fitting O-ring seal.
All vehicles
6. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts
because heat damage may occur. Damage
may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F).
NOTE: Do not use power tools.
Remove the TP sensor.
1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the
top TP sensor bolt ear reaches approximately
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page
3201
55°C (130°F), this should take no more than 3 minutes using a 1100-watt heat gun. The heat gun
should be about an 25.4 mm (1 in) away from the ETB.
2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature
measuring device, such as a digital temperature
laser or infrared thermometer, while heating the ETB.
3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard.
4. Using hand tools, remove the remaining bolt and discard.
5. Remove and discard the TP sensor.
Installation
All vehicles
1. NOTE: Do not use power tools.
Install the new TP sensor.
- Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in).
Vehicles equipped with a 4.6L (3V) engine
2. Install a new O-ring seal and position the heated PCV fitting and install the 2 bolts.
3. Connect the heated PCV fitting electrical connector.
4. Connect the PCV hose to the heated PCV fitting.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page
3202
All vehicles
5. Connect the TP sensor electrical connector.
6. Install the ACL outlet pipe.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Page
3206
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Page
3207
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Page
3208
Transmission Position Switch/Sensor: Adjustments
5R55S
Transmission Range (TR) Sensor Adjustment
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 Transmission Range (TR) sensor connector.
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable end from the manual control lever.
6. Remove the manual control lever nut and the manual control lever.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Page
3209
7. Loosen but do not remove the TR sensor screws.
8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence.
- Tighten to 8 Nm (71 lb-in).
9. Install the manual control lever and manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
11. Reconnect the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Page
3210
12. Reinstall the rubber boot over the TR 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 (V6-4.0L (2009))
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 > Page
3211
Transmission Position Switch/Sensor: Service and Repair
5R55S
Digital Transmission Range (TR) Sensor
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
3. Move the TR sensor connector boot back to gain access to the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Page
3212
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable from the manual control lever.
6. Remove the manual control lever nut.
7. Remove the TR sensor.
Installation
1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to
prevent damage to the sensor.
Install the TR sensor and loosely install the TR sensor screw and washer (2 required).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Page
3213
2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual control lever must be in the NEUTRAL position.
Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence. Tighten to 8 Nm (71 lb-in).
3. Install the manual control lever and the manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
5. Connect the TR sensor connector.
6. Move the TR sensor connector boot back over the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Page
3214
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output
Shaft Speed (OSS) Sensor
Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor
Engine Control Components
Output Shaft Speed (OSS) Sensor
The OSS sensor provides the PCM with information about the rotational speed of an output shaft.
The PCM uses the information to control and diagnose powertrain behavior. In some applications,
the sensor is also used as the source of vehicle speed. The sensor may be physically located in
different places on the vehicle, depending upon the specific application. The design of each speed
sensor is unique and depends on which powertrain control feature uses the information that is
generated.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output
Shaft Speed (OSS) Sensor > Page 3219
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS)
Engine Control Components
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 speed, 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.
Typical Vehicle Speed Sensor (VSS)
Typical Vehicle Speed Sensor (VSS)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 09-22-4 > Nov >
09 > A/C, Engine Controls - MIL ON/DTC P2135 Set
Throttle Position Sensor: Customer Interest A/C, Engine Controls - MIL ON/DTC P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 09-22-4 > Nov >
09 > A/C, Engine Controls - MIL ON/DTC P2135 Set > Page 3228
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: >
09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC P2135 Set
Throttle Position Sensor: All Technical Service Bulletins A/C, Engine Controls - MIL ON/DTC
P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: >
09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC P2135 Set > Page 3234
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Page 3235
Throttle Position Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Page 3236
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Page 3237
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > Electronic Throttle Body (ETB) Throttle Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle
Position Sensor
Engine Control Components
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. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) See: Electronic Throttle Control Module/Description and Operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > Electronic Throttle Body (ETB) Throttle Position Sensor > Page 3240
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
Engine Control Components
Throttle Position (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, four operating conditions are determined by the
PCM from the TP. These 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
Typical TP Sensor
Typical TP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > Page 3241
Throttle Position Sensor: Service and Repair
Throttle Position (TP) Sensor
Removal
All vehicles
1. Remove the Air Cleaner (ACL) outlet pipe.
2. Disconnect the Throttle Position (TP) sensor electrical connector.
Vehicles equipped with a 4.6L (3V) engine
3. Disconnect the PCV hose from the heated PCV fitting.
4. Disconnect the heated PCV fitting electrical connector.
5. Remove the 2 bolts and the heated PCV fitting.
- Remove and discard the heated PCV fitting O-ring seal.
All vehicles
6. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts
because heat damage may occur. Damage
may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F).
NOTE: Do not use power tools.
Remove the TP sensor.
1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the
top TP sensor bolt ear reaches approximately
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > Page 3242
55°C (130°F), this should take no more than 3 minutes using a 1100-watt heat gun. The heat gun
should be about an 25.4 mm (1 in) away from the ETB.
2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature
measuring device, such as a digital temperature
laser or infrared thermometer, while heating the ETB.
3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard.
4. Using hand tools, remove the remaining bolt and discard.
5. Remove and discard the TP sensor.
Installation
All vehicles
1. NOTE: Do not use power tools.
Install the new TP sensor.
- Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in).
Vehicles equipped with a 4.6L (3V) engine
2. Install a new O-ring seal and position the heated PCV fitting and install the 2 bolts.
3. Connect the heated PCV fitting electrical connector.
4. Connect the PCV hose to the heated PCV fitting.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > Page 3243
All vehicles
5. Connect the TP sensor electrical connector.
6. Install the ACL outlet pipe.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations
Transmission Position Switch/Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3247
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3248
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3249
Transmission Position Switch/Sensor: Adjustments
5R55S
Transmission Range (TR) Sensor Adjustment
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 Transmission Range (TR) sensor connector.
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable end from the manual control lever.
6. Remove the manual control lever nut and the manual control lever.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3250
7. Loosen but do not remove the TR sensor screws.
8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence.
- Tighten to 8 Nm (71 lb-in).
9. Install the manual control lever and manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
11. Reconnect the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3251
12. Reinstall the rubber boot over the TR 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3252
Transmission Position Switch/Sensor: Service and Repair
5R55S
Digital Transmission Range (TR) Sensor
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
3. Move the TR sensor connector boot back to gain access to the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3253
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable from the manual control lever.
6. Remove the manual control lever nut.
7. Remove the TR sensor.
Installation
1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to
prevent damage to the sensor.
Install the TR sensor and loosely install the TR sensor screw and washer (2 required).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3254
2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual control lever must be in the NEUTRAL position.
Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence. Tighten to 8 Nm (71 lb-in).
3. Install the manual control lever and the manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
5. Connect the TR sensor connector.
6. Move the TR sensor connector boot back over the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3255
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Description and Operation
Variable Valve Timing Actuator: Description and Operation
Variable Camshaft Timing (VCT) System
Overview
The VCT system enables rotation of the camshaft(s) relative to the crankshaft rotation as a function
of engine operating conditions. There are four 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 four 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.
The VCT system knocking and noise concerns are diagnosed in the Testing and Inspection
section. For additional information, refer to the Engine System - General Information. Verification of
incorrect VCT phasing on a warm engine operating below 1500 RPM can be isolated using a
stethoscope and by monitoring the VCTADV, VCTADVERR and VCTDC PIDs using a scan tool. If
the VCT phaser does not maintain correct valve timing, low oil pressure or oil flow restrictions are
primary possible causes. Verify correct oil pressure and flow, refer to the Engine System - General
Information.
Variable Camshaft Timing (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 indicates 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), engine coolant
temperature (ECT), engine oil temperature (EOT), CMP,
throttle position (TP), mass air flow (MAF), and CKP sensors 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Description and Operation > Page 3259
achieved. A difference between the desired and actual camshaft position represents a position
error in the PCM VCT control loop. The PCM disables the VCT and places the camshaft in a
default position if a concern is detected. A related DTC is also set when the concern is detected.
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 two 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.
VCT System
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid >
Component Information > Locations > VCT Solenoid 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid >
Component Information > Locations > VCT Solenoid 1 > Page 3264
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid >
Component Information > Diagrams > VCT Solenoid 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid >
Component Information > Diagrams > VCT Solenoid 1 > Page 3267
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid >
Component Information > Diagrams > Page 3268
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor
Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor
Engine Control Components
Output Shaft Speed (OSS) Sensor
The OSS sensor provides the PCM with information about the rotational speed of an output shaft.
The PCM uses the information to control and diagnose powertrain behavior. In some applications,
the sensor is also used as the source of vehicle speed. The sensor may be physically located in
different places on the vehicle, depending upon the specific application. The design of each speed
sensor is unique and depends on which powertrain control feature uses the information that is
generated.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor > Page 3273
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS)
Engine Control Components
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 speed, 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.
Typical Vehicle Speed Sensor (VSS)
Typical Vehicle Speed Sensor (VSS)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid >
Component Information > Description and Operation
Air Diverter Solenoid: Description and Operation
Engine Control Components
Secondary Air Injection (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.
Secondary AIR Bypass Solenoid
Secondary AIR Bypass Solenoid
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve >
Component Information > Description and Operation
Air Diverter Valve: Description and Operation
Engine Control Components
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.
Secondary AIR Diverter Valve
Secondary AIR Diverter Valve
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump >
Component Information > Description and Operation
Air Injection Pump: Description and Operation
Engine Control Components
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 mass air flow/intake air temperature sensor. For additional
information on the secondary AIR injection system, refer to Secondary Air Injection (AIR) System
See: Description and Operation.
Secondary Air Pump
Secondary Air Pump
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
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 (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 two 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 (PZEVs) use three HO2Ss. The stream 1 sensor (HO2S11) located before the
catalyst is used for primary fuel control, the stream 2 sensor (HO2S12) is used to monitor the
light-off catalyst, and the stream 3 sensor (HO2S13) located after the catalyst is used for long term
fuel trim control to optimize catalyst efficiency (fore aft oxygen sensor control).
V-Engines
V-Engines
In-Line Engines
In-Line Engines
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 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 three way catalytic converter (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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 3288
catalyst.
Three Way Catalytic Converter (TWC) Conversion Efficiency
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.
TWC Conversion Efficiency Chart
TWC Conversion Efficiency Chart
Exhaust System
The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the
atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the
catalytic converter through the front exhaust pipe. 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 three HO2Ss 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.
Typical Bank 1 Catalyst 2 H2OS Configuration
Typical Bank 1 Catalyst 2 HO2S Configuration
Typical Bank 1 Catalyst 3 H2OS Configuration
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 3289
Typical Bank 1 Catalyst 3 HO2S Configuration
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 two light off catalysts,
forming a Y pipe configuration. For an exact configuration of the catalyst and exhaust system for a
specific vehicle, refer to the Exhaust System for the exhaust system exploded view.
Three Way Catalytic (TWC) Converter
The TWC contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The
TWC 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. For
additional information on the HO2S, refer to Engine Control Components See: Computers and
Control Systems/Description and Operation/Engine Control Components.
Muffler
Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase
the life of the product. The muffler reduces the level of noise produced by the engine, and also
reduces the noise produced by exhaust gases as they travel from the catalytic converter to the
atmosphere.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 3290
Catalytic Converter: Service and Repair
Exhaust System - Exploded View
4.0L Explorer Sport Trac
NOTE: Vehicle body removed for clarity.
4.6L Explorer Sport Trac
NOTE: Vehicle body removed for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 3291
4.0L Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
NOTE: Premier exhaust shown, standard exhaust similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 3292
4.6L Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
NOTE: Premier exhaust shown, standard exhaust similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 3293
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams > Page 3298
Canister Purge Control Valve: Description and Operation
Engine Control Components
Evaporative Emission (EVAP) Canister Purge Valve
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. For E-Series, Escape/Mariner,
Expedition, F-Series, and Navigator, the PCM outputs a duty cycle between 0% and 100% to
control the EVAP canister purge valve. For all others, the PCM outputs a variable current between
0 mA and 1,000 mA to control the EVAP canister purge valve.
Typical EVAP Canister Purge Valve
Typical EVAP Canister Purge Valve (Part 1)
Typical EVAP Canister Purge Valve (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams > Page 3299
Canister Purge Control Valve: Service and Repair
Evaporative Emission Canister Purge Valve
Removal and Installation
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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: 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.
- Carry out the Evaporative Emission System Leak Test. For additional information, refer to
Evaporative Emission System Leak Test See: Testing and Inspection.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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: 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.
- Carry out the Evaporative Emission System Leak Test. For additional information, refer to
Evaporative Emission System Leak Test See: Testing and Inspection.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair
Canister Vent Valve: Service and Repair
Fuel Vapor Vent Valve
Removal and Installation
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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: 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 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.
- Carry out the Evaporative Emission System Leak Test. For additional information, refer to
Evaporative Emission System Leak Test See: Testing and Inspection.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
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.
Typical Canister Vent (CV) Solenoid
Typical Canister Vent (CV) Solenoid
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Locations
Leak Detection Valve: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Locations > Page 3313
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Locations > Page 3314
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Module > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Module > Component Information > Locations > Page 3319
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Solenoid > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components Exploded View
EGR Control Solenoid: Service and Repair Exhaust Gas Recirculation (EGR) System Components
- Exploded View
Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Solenoid > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components Exploded View > Page 3324
EGR Control Solenoid: Service and Repair Exhaust Gas Recirculation (EGR) System Module
Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC
Removal and Installation
1. Disconnect the EGR system module electrical and vacuum connectors.
2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting.
- To install, tighten to 40 Nm (30 lb-ft).
3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle
facing the intake manifold.
Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket.
- To install, tighten to 25 Nm (18 lb-ft).
4. NOTE: The EGR system module sealing surfaces are soft metals.
Carefully clean the EGR system module sealing surfaces.
5. To install, reverse the removal procedure.
- Install a new EGR system module gasket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
Exhaust Gas Recirculation (EGR) Vacuum Regulator Solenoid
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.
EGR Vacuum Regulator Solenoid
EGR Vacuum Regulator Solenoid
EGR Vacuum Regulator Solenoid Duty Cycle Graph
EGR Vacuum Regulator Solenoid Data
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Description and Operation
EGR Tube: Description and Operation
Engine Control Components
Exhaust Gas Recirculation (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 two pressure pick-up tubes. The internal metering orifice creates
a measurable pressure drop across it as the EGR valve opens and closes. This pressure
differential across the orifice is picked up by the differential pressure feedback EGR sensor which
provides feedback to the PCM.
EGR Orifice Tube Assembly
EGR Orifice Tube Assembly
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View
EGR Tube: Service and Repair Exhaust Gas Recirculation (EGR) System Components - Exploded
View
Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View
> Page 3333
EGR Tube: Service and Repair Exhaust Gas Recirculation (EGR) System Module Tube
Exhaust Gas Recirculation (EGR) System Module Tube - 4.0L SOHC
Removal and Installation
1. Disconnect the EGR system module-to-exhaust manifold tube upper fitting.
- To install, tighten to 40 Nm (30 lb-ft).
2. Disconnect the EGR system module-to-exhaust manifold tube lower fitting and remove the tube.
- To install, tighten to 40 Nm (30 lb-ft).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Electric Exhaust Gas Recirculation (EEGR) Valve
EGR Valve: Description and Operation Electric Exhaust Gas Recirculation (EEGR) Valve
Engine Control Components
Electric Exhaust Gas Recirculation (EEGR) Valve
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).
EEGR Motor/Valve Assembly
EEGR Motor/Valve Assembly
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Electric Exhaust Gas Recirculation (EEGR) Valve > Page 3338
EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) System Module (ESM)
Engine Control Components
Exhaust Gas Recirculation (EGR) System Module (ESM)
The ESM is an integrated differential pressure feedback EGR system that functions in the same
manner as a conventional differential pressure feedback EGR system. The various system
components have been integrated into a single component called the ESM. The flange of the valve
portion of the ESM bolts directly to the intake manifold with a metal gasket that forms the metering
orifice. This arrangement increases system reliability, response time, and system precision. By
relocating the EGR orifice from the exhaust to the intake side of the EGR valve, the downstream
pressure signal measures manifold absolute pressure (MAP). This MAP signal is used for EGR
correction and inferred barometric pressure (BARO) at ignition on. The system provides the PCM
with a differential pressure feedback EGR signal, identical to a traditional differential pressure
feedback EGR system.
ESM
ESM (Part 1)
ESM (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Electric Exhaust Gas Recirculation (EEGR) Valve > Page 3339
EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) Valve
Engine Control Components
Exhaust Gas Recirculation (EGR) Valve
The EGR valve in the differential pressure feedback EGR system is a conventional,
vacuum-actuated valve. 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.
Typical EGR Valve
Typical EGR Valve (Part 1)
Typical EGR Valve (Part 2)
EGR Flow Rate Graph
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View
EGR Valve: Service and Repair Exhaust Gas Recirculation (EGR) System Components - Exploded
View
Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View
> Page 3342
EGR Valve: Service and Repair Exhaust Gas Recirculation (EGR) System Module
Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC
Removal and Installation
1. Disconnect the EGR system module electrical and vacuum connectors.
2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting.
- To install, tighten to 40 Nm (30 lb-ft).
3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle
facing the intake manifold.
Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket.
- To install, tighten to 25 Nm (18 lb-ft).
4. NOTE: The EGR system module sealing surfaces are soft metals.
Carefully clean the EGR system module sealing surfaces.
5. To install, reverse the removal procedure.
- Install a new EGR system module gasket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
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
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
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.
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR)
System Components - Exploded View
Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System
Components - Exploded View
Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR)
System Components - Exploded View > Page 3348
Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System
Module
Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC
Removal and Installation
1. Disconnect the EGR system module electrical and vacuum connectors.
2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting.
- To install, tighten to 40 Nm (30 lb-ft).
3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle
facing the intake manifold.
Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket.
- To install, tighten to 25 Nm (18 lb-ft).
4. NOTE: The EGR system module sealing surfaces are soft metals.
Carefully clean the EGR system module sealing surfaces.
5. To install, reverse the removal procedure.
- Install a new EGR system module gasket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Diagrams > Page 3353
Positive Crankcase Ventilation Valve: Service and Repair
Positive Crankcase Ventilation (PCV) Valve - 4.0L SOHC
Removal and Installation
1. Disconnect the PCV valve electrical connector.
2. Disconnect the PCV valve hose.
3. NOTE: If the PCV valve is removed from the valve cover, a new PCV valve must be installed.
Rotate the PCV valve counterclockwise and remove it from the valve cover.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control
Systems > EGR Control Module > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control
Systems > EGR Control Module > Component Information > Locations > Page 3358
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
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
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
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.
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust
Gas Recirculation (EGR) System Components - Exploded View
Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System
Components - Exploded View
Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust
Gas Recirculation (EGR) System Components - Exploded View > Page 3365
Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System
Module
Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC
Removal and Installation
1. Disconnect the EGR system module electrical and vacuum connectors.
2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting.
- To install, tighten to 40 Nm (30 lb-ft).
3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle
facing the intake manifold.
Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket.
- To install, tighten to 25 Nm (18 lb-ft).
4. NOTE: The EGR system module sealing surfaces are soft metals.
Carefully clean the EGR system module sealing surfaces.
5. To install, reverse the removal procedure.
- Install a new EGR system module gasket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Specifications
Fuel Pressure: Specifications
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Specifications > Page 3370
Fuel Pressure: Testing and Inspection
Fuel System Pressure Test
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.
WARNING: 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.
WARNING: 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. Release the fuel system pressure. For additional information, refer to Fuel System Pressure
Release See: Fuel Filter/Fuel Pressure Release/Service
and Repair.
2. Disconnect the battery ground cable.
3. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. For additional information, refer
to Spring Lock Couplings See: Fuel Line
Coupler/Service and Repair/Spring Lock Couplings.
4. NOTE: 4.6L shown, 4.0L similar.
Install the Fuel Pressure Test Kit in line between the fuel supply tube and fuel rail.
5. NOTE: The Inertia Fuel Shutoff (IFS) switch electrical connector was disconnected during fuel
system pressure release.
Connect the IFS switch electrical connector.
6. Connect the battery ground cable.
7. 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.
8. Test the fuel system pressure to make sure it is within the specified range. For additional
information, refer to Specifications.
9. NOTE: 4.6L shown, 4.0L similar.
NOTE: 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 Fuel Pressure Test
Kit and relieve the fuel system pressure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Specifications > Page 3371
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
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. 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.
NOTE: It may be necessary to reposition the lower end of the door jam weatherstripping to remove
the front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the Inertia Fuel Shutoff (IFS) switch electrical connector.
4. Start the engine and allow it to idle until it stalls.
5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail
pressure has been released.
6. Turn the ignition switch to the OFF position.
7. When the fuel system service is complete, reconnect the IFS switch electrical connector.
8. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before
starting the engine.
9. Start the vehicle and check the fuel system for leaks.
10. Install the front passenger side interior kick panel.
11. Install the front passenger door frame scuff plate.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 Hot Idle ............................................................................................................
.......................................................................................... 750 - 820 RPM
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3 nuts and the accelerator pedal assembly.
- To install, tighten to 7 Nm (62 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Service and Repair > Accelerator Pedal - Fixed > Page 3382
Accelerator Pedal: Service and Repair Accelerator Pedal - Adjustable
Accelerator Pedal - Adjustable
Removal and Installation
1. The adjustable accelerator pedal and adjustable brake pedal must be serviced as a unit.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor >
Component Information > Locations > Page 3386
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor >
Component Information > Locations > Page 3387
Accelerator Pedal Position Sensor: Description and Operation
Engine Control Components
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
There are two 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 two
pedal position signals make sure the PCM receives a correct input even if one 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 two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six
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 (TP) 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. For additional information, refer
to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic
Throttle Control Module/Description and Operation.
2-Track APP Sensor
Typical 2-Track APP Sensor
3-Track APP Sensor
There are three 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 three pedal position signals make sure the PCM
receives a correct input even if one 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 two reference voltage circuits, two signal
return circuits, and three signal circuits (a total of seven 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. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description
and Operation.
3-Track APP Sensor
Typical 3-Track APP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Intake Air System Components - Exploded View
Air Filter Element: Service and Repair Intake Air System Components - Exploded View
Intake Air System Components - Exploded View
Coolant Expansion Tank
Intake Air System Components (4.0L SOHC)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 3393
Intake Air System Components - 4.6L (3V)
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 3394
Air Filter Element: Service and Repair Air Cleaner Element
Air Cleaner Element
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 element.
6. NOTE: Clean the inside of the ACL tray.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations
Air Flow Meter/Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 3398
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 3399
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 3400
Air Flow Meter/Sensor: Description and Operation
Engine Control Components
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 (TCC) 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 IAT sensor.
The hot wire electronic sensing element must be replaced as an assembly. Replacing only the
element may change the air flow calibration.
Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT
Sensor Wire Where Applicable) Terminals
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
Typical Mass Air Flow (MAF) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 3401
Typical Drop-in Mass Air Flow (MAF) Sensor
Typical Drop-in Mass Air Flow (MAF) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 3402
Air Flow Meter/Sensor: Service and Repair
Mass Air Flow (MAF) Sensor - 4.0L SOHC
Removal and Installation
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the 2 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 (V6-4.0L (2009))
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
Engine Control Components
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 is detected by the inability to pull vacuum in the fuel tank after a fueling event.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
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. 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.
NOTE: It may be necessary to reposition the lower end of the door jam weatherstripping to remove
the front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the Inertia Fuel Shutoff (IFS) switch electrical connector.
4. Start the engine and allow it to idle until it stalls.
5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail
pressure has been released.
6. Turn the ignition switch to the OFF position.
7. When the fuel system service is complete, reconnect the IFS switch electrical connector.
8. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before
starting the engine.
9. Start the vehicle and check the fuel system for leaks.
10. Install the front passenger side interior kick panel.
11. Install the front passenger door frame scuff plate.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications > Page 3414
Fuel Injector: Pressure, Vacuum and Temperature Specifications
Fuel Injector Flow and Leakage ...................................................................................... Refer to
Pinpoint Test HC12 at Computers and Control Systems.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3417
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3418
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3419
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3420
Fuel Injector: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3421
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3422
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3423
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3424
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3425
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Page 3426
Fuel Injector: Description and Operation
Engine Control Components
Fuel Injectors
Note: 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. Install a
new fuel injector if the flow is checked and found to be out of specification.
Typical Fuel Injector
Typical Fuel Injector (Part 1)
Typical Fuel Injector (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Fuel Rail and Fuel Injector - Exploded View
Fuel Injector: Service and Repair Fuel Rail and Fuel Injector - Exploded View
Fuel Rail and Fuel Injector - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
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.
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.
WARNING: 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.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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: 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.
NOTICE: 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.
NOTICE: 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. For additional information, refer to Fuel System Pressure
Release See: Fuel Filter/Fuel Pressure Release/Service
and Repair.
2. Disconnect the battery ground cable.
3. Disconnect the safety clip from the fuel tube.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3433
4. Install the Spring Lock Coupling Disconnect 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.
NOTE: Lubricate the spring lock coupling with clean engine oil.
Align the fuel tube spring lock coupling and push together until a click is heard.
3. Pull on the spring lock coupling to make sure it is fully seated. Install the fuel tube safety clip on
the male end.
4. Connect the battery ground cable.
Disconnect - Type II
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3434
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.
WARNING: 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.
WARNING: 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.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are
always present and may be ignited. Failure to follow these instructions may result in serious
personal injury.
NOTICE: 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.
NOTICE: 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. For additional information, refer to Fuel System Pressure
Release See: Fuel Filter/Fuel Pressure Release/Service
and Repair.
2. Disconnect the battery ground cable.
3. Remove the fuel tube safety clip.
4. Install the Spring Lock Coupling Disconnect Tool.
5. Close and push the Spring Lock Coupling Disconnect Tool into the open side of the cage.
6. Separate the spring lock coupling.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3435
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.
NOTE: 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.
4. Install the fuel tube safety clip.
5. Connect the battery ground cable.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3436
Fuel Line Coupler: Service and Repair Quick Connect Coupling
Quick Connect Coupling
Disconnect - Type I
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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: 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.
WARNING: 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.
WARNING: 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.
NOTICE: 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.
NOTICE: 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.
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. For additional information, refer
to Fuel System Pressure Release See: Fuel
Filter/Fuel Pressure Release/Service and Repair.
2. Disconnect the battery ground cable.
3. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components
which may cause fuel leaks.
Unclip the locking tab.
4. Depress the tabs and press the clip downward.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3437
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.
NOTE: Lubricate the quick connect coupling with clean engine oil.
Connect the quick connect coupling.
3. Push the clip up into the quick connect coupling. Pull on the tube to make sure it is seated
correctly.
4. Clip the locking tab in place.
5. Connect the battery ground cable.
Disconnect - Type II
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are
always present and may be ignited. Failure to follow these instructions may result in
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3438
serious personal injury.
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.
WARNING: 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.
WARNING: 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.
NOTICE: 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.
NOTICE: 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.
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. For additional information, refer
to Fuel System Pressure Release See: Fuel
Filter/Fuel Pressure Release/Service and Repair.
2. Disconnect the battery ground cable.
3. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components
which may cause fuel leaks.
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: Make sure the fuel tube clicks into place when installing the tube. To make sure that the
fuel tube is fully seated, pull on the tube.
NOTE: Apply clean engine oil to O-ring seals.
Install the quick connect coupling onto the tube until it is fully seated.
3. Connect the battery ground cable.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3439
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.
WARNING: 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.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are
always present and may be ignited. Failure to follow these instructions may result in serious
personal injury.
NOTICE: 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.
NOTICE: 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.
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. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components
which may cause fuel leaks.
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.
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.
NOTE: Apply clean engine oil to O-ring seals.
Release the locking tab and install the quick connect coupling onto the fitting.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3440
3. Position the locking tab into the latched position.
Disconnect - Type IV
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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: 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.
WARNING: 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.
WARNING: 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.
NOTICE: 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.
NOTICE: 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.
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. For additional information, refer
to Fuel System Pressure Release See: Fuel
Filter/Fuel Pressure Release/Service and Repair.
2. Disconnect the battery ground cable.
3. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components
which may cause fuel leaks.
Compress the clip legs and push the clip into the quick connect coupling.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3441
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.
NOTE: Apply clean engine oil to O-ring seals.
Fully insert the male tube end in the quick connect coupling and push the clip downward to lock the
fuel tubes together.
3. Pull on the connection to make sure it is fully engaged.
4. Connect the battery ground cable.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations
Fuel Pressure Sensor/Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations > Page 3445
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations > Page 3446
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations > Page 3447
Fuel Pressure Sensor/Switch: Description and Operation
Engine Control Components
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.
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations > Page 3448
Fuel Pressure Sensor/Switch: Service and Repair
Fuel Rail Pressure and Temperature Sensor - 4.0L SOHC
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.
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.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Remove the intake manifold.
4. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
5. Remove the 2 bolts and the fuel rail pressure and temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. Remove and discard the O-ring seal.
7. NOTICE: Use an O-ring seal made of special fuel resistant material. Fuel will damage ordinary
O-ring seals and may cause the fuel
system to leak.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations > Page 3449
NOTICE: Do not reuse the O-ring seal. The removal and installation process may damage the used
O-ring seals and cause the fuel system to leak.
To install, reverse the removal procedure.
- Lubricate the new O-ring seal with clean engine oil.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications
Fuel Pressure: Specifications
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications > Page 3454
Fuel Pressure: Testing and Inspection
Fuel System Pressure Test
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.
WARNING: 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.
WARNING: 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. Release the fuel system pressure. For additional information, refer to Fuel System Pressure
Release See: Fuel Filter/Fuel Pressure Release/Service
and Repair.
2. Disconnect the battery ground cable.
3. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. For additional information, refer
to Spring Lock Couplings See: Fuel Line
Coupler/Service and Repair/Spring Lock Couplings.
4. NOTE: 4.6L shown, 4.0L similar.
Install the Fuel Pressure Test Kit in line between the fuel supply tube and fuel rail.
5. NOTE: The Inertia Fuel Shutoff (IFS) switch electrical connector was disconnected during fuel
system pressure release.
Connect the IFS switch electrical connector.
6. Connect the battery ground cable.
7. 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.
8. Test the fuel system pressure to make sure it is within the specified range. For additional
information, refer to Specifications.
9. NOTE: 4.6L shown, 4.0L similar.
NOTE: 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 Fuel Pressure Test
Kit and relieve the fuel system pressure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications > Page 3455
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control
Unit > Component Information > Locations > Fuel Pump Driver Module
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control
Unit > Component Information > Locations > Fuel Pump Driver Module > Page 3460
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control
Unit > Component Information > Locations > Page 3461
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control
Unit > Component Information > Locations > Page 3462
Fuel Pump Control Unit: Service and Repair
Fuel Pump Driver Module (FPDM) - Explorer, Mountaineer
Removal and Installation
1. Remove the RH rear quarter trim panel.
2. Disconnect the Fuel Pump Driver Module (FPDM) electrical connector.
3. Remove the 2 bolts and the FPDM.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 3466
Fuel Pump Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 3467
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service and Repair > Fuel Rail
Fuel Rail: Service and Repair Fuel Rail
Fuel Rail
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.
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.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are
always present and may be ignited. Failure to follow these instructions may result in serious
personal injury.
NOTICE: If used as a leverage device, the fuel rail may be damaged. Care must be taken when
working around the fuel rail.
NOTE: During the repair or replacement of fuel-related components, cap, tape or otherwise
appropriately protect all liquid and vapor fuel openings to prevent the ingress of dirt or other
contamination. Remove all caps, tape and other protective materials prior to installation.
1. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Disconnect the spring lock coupling.
4. Remove the intake manifold.
5. Remove the fuel supply tube bracket bolt.
- To install, tighten to 8 Nm (71 lb-in).
6. Disconnect the 6 fuel injector electrical connectors.
7. Disconnect the fuel pressure and temperature sensor electrical and vacuum connectors.
8. Remove the 4 bolts and the fuel rail and injectors as an assembly.
- To install, tighten to 23 Nm (17 lb-ft).
9. Remove the fuel injectors. Remove and discard the O-ring seals.
10. NOTICE: 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.
NOTICE: 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.
NOTE: Install new fuel injector O-ring seals and lubricate them with clean engine oil.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service and Repair > Fuel Rail > Page 3472
Fuel Rail: Service and Repair Fuel Rail Supply Tube
Fuel Rail Supply Tube
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.
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.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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: During the repair or replacement of fuel-related components, cap, tape or otherwise
appropriately protect all liquid and vapor fuel openings to prevent the ingress of dirt or other
contamination. Remove all caps, tape and other protective materials prior to installation.
1. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Remove the intake manifold.
4. Disconnect the fuel rail supply tube spring lock coupling.
5. Remove the fuel rail supply tube bracket bolt.
- To install, tighten to 8 Nm (71 lb-in).
6. Remove the 4 bolts and the fuel rail supply tube.
- To install, tighten to 6 Nm (53 lb-in).
7. NOTICE: 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.
NOTICE: 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 rail supply tube O-ring seals.
8. To install, reverse the removal procedure.
- Lubricate the new O-ring seals with clean engine oil prior to installation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service and Repair > Fuel Rail > Page 3473
Fuel Rail: Service and Repair Fuel Rail and Fuel Injector - Exploded View
Fuel Rail and Fuel Injector - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View
Fuel Supply Line: Service and Repair Fuel Tank and Filler Pipe - Exploded View
Fuel Tank and Filler Pipe - Exploded View
Explorer Sport Trac
NOTE: Vehicle body removed from art for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3478
Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3479
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3480
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3481
Fuel Supply Line: Service and Repair Fuel Lines and Fuel Filter - Exploded View
Fuel Lines and Fuel Filter - Exploded View
Explorer Sport Trac
NOTE: 4.6L shown, 4.0L similar.
NOTE: Vehicle body removed from art for clarity.
Explorer/Mountaineer
NOTE: 4.6L shown, 4.0L similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3482
NOTE: Vehicle body removed from art for clarity.
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3483
Fuel Supply Line: Service and Repair Fuel Lines
Fuel Lines
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.
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.
WARNING: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View
Fuel Filler Hose: Service and Repair Fuel Tank and Filler Pipe - Exploded View
Fuel Tank and Filler Pipe - Exploded View
Explorer Sport Trac
NOTE: Vehicle body removed from art for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3489
Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3490
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3491
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3492
Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe
Fuel Tank Filler Pipe
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.
WARNING: 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.
WARNING: 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).
Explorer Sport Trac
3. Open the fuel tank filler cap.
Explorer/Mountaineer
4. Remove the fuel tank filler pipe upper retainer.
5. NOTE: Body panel and fuel door removed from art for clarity.
Depress the 2 tabs on the fresh air vent tube in the fuel filler door pocket and disconnect the fresh
air vent tube from the inner fenderwell.
All vehicles
6. Remove the 3 bolts.
- To install, tighten to 1 Nm (9 lb-in).
7. Disconnect the fuel filler pipe vapor tube-to-Fuel Tank Pressure (FTP) 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3493
- To install, tighten to 15 Nm (133 lb-in).
11. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams
Fuel Gauge Sender: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Fuel Pump (FP) Module
Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module
Engine Control Components
Fuel Pump (FP) Module
The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is
located inside the FP module reservoir and supplies fuel through the FP module manifold to the
engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a
check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Mechanical Returnless Fuel Pump (FP) Module
Typical Mechanical Returnless Fuel Pump (FP) Module
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Fuel Pump (FP) Module > Page 3499
Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module and Reservoir
Engine Control Components
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 ignition has been turned off to minimize starting
concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low
tank fill levels.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Page 3500
Fuel Gauge Sender: Service and Repair
Fuel Tank and Filler Pipe - Exploded View
Explorer Sport Trac
NOTE: Vehicle body removed from art for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Page 3501
Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Page 3502
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Page 3503
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
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.
5. Remove the bolt and the fuel tank rear support strap.
- To install, tighten to 48 Nm (35 lb-ft).
6. Remove the nut and the fuel tank front support strap.
- To install, tighten to 48 Nm (35 lb-ft).
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Description and Operation > Fuel Pump (FP) Module
Fuel Tank Unit: Description and Operation Fuel Pump (FP) Module
Engine Control Components
Fuel Pump (FP) Module
The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is
located inside the FP module reservoir and supplies fuel through the FP module manifold to the
engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a
check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Mechanical Returnless Fuel Pump (FP) Module
Typical Mechanical Returnless Fuel Pump (FP) Module
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Description and Operation > Fuel Pump (FP) Module > Page 3511
Fuel Tank Unit: Description and Operation Fuel Pump (FP) Module and Reservoir
Engine Control Components
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 ignition has been turned off to minimize starting
concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low
tank fill levels.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Locations
Fuel Temperature Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Locations > Page 3515
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Locations > Page 3516
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Locations > Page 3517
Fuel Temperature Sensor: Description and Operation
Engine Control Components
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.
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Locations > Page 3518
Fuel Temperature Sensor: Service and Repair
Fuel Rail Pressure and Temperature Sensor - 4.0L SOHC
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.
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.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Remove the intake manifold.
4. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
5. Remove the 2 bolts and the fuel rail pressure and temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. Remove and discard the O-ring seal.
7. NOTICE: Use an O-ring seal made of special fuel resistant material. Fuel will damage ordinary
O-ring seals and may cause the fuel
system to leak.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Locations > Page 3519
NOTICE: Do not reuse the O-ring seal. The removal and installation process may damage the used
O-ring seals and cause the fuel system to leak.
To install, reverse the removal procedure.
- Lubricate the new O-ring seal with clean engine oil.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
Idle Air Control (IAC) Valve
Note: The IAC valve assembly is not adjustable and cannot be cleaned, also some IAC valves are
normally open and others are normally closed. Some IAC valves require engine vacuum to
operate.
The IAC valve assembly controls the engine idle speed and provides a dashpot function. The IAC
valve assembly meters intake air around the throttle plate through a bypass within the IAC valve
assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals
the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the
IAC valve to control the amount of bypassed air. The PCM monitors engine RPM and increases or
decreases the IAC duty cycle in order to achieve the desired RPM.
The PCM uses the IAC valve assembly to control:
- no touch start
- cold engine fast idle for rapid warm-up
- idle (corrects for engine load)
- stumble or stalling on deceleration (provides a dashpot function)
- over-temperature idle boost
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 3526
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 3527
Inertia Fuel Shutoff Switch: Description and Operation
Engine Control Components
Inertia Fuel Shut-off (IFS) Switch
The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is
to shut off the fuel pump if a collision occurs. It consists of a steel cone held in place by a magnet.
When a sharp impact occurs, the cone 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.
Typical Inertia Fuel Shut-off (IFS) Switch
Typical Inertia Fuel Shut-off (IFS) Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 3528
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.
NOTE: 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 2 bolts and the IFS switch.
- To install, tighten to 2 Nm (18 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component
Information > Service and Repair > Intake Air System Components - Exploded View
Intake Air Duct: Service and Repair Intake Air System Components - Exploded View
Intake Air System Components - Exploded View
Coolant Expansion Tank
Intake Air System Components (4.0L SOHC)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component
Information > Service and Repair > Intake Air System Components - Exploded View > Page 3533
Intake Air System Components - 4.6L (3V)
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component
Information > Service and Repair > Intake Air System Components - Exploded View > Page 3534
Intake Air Duct: Service and Repair Air Cleaner Outlet Pipe
Air Cleaner Outlet Pipe
Removal and Installation
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. Disconnect the brake booster vacuum hose from the ACL outlet pipe.
All vehicles
3. Disconnect the crankcase breather hose from the ACL outlet pipe.
4. Loosen the clamps and remove the ACL outlet pipe.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 3538
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 3539
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 Driver Module
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 Driver Module > Page 3545
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3546
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3547
Fuel Pump Control Unit: Service and Repair
Fuel Pump Driver Module (FPDM) - Explorer, Mountaineer
Removal and Installation
1. Remove the RH rear quarter trim panel.
2. Disconnect the Fuel Pump Driver Module (FPDM) electrical connector.
3. Remove the 2 bolts and the FPDM.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3551
Fuel Pump Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3552
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3556
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3557
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3562
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3563
Accelerator Pedal Position Sensor: Description and Operation
Engine Control Components
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
There are two 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 two
pedal position signals make sure the PCM receives a correct input even if one 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 two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six
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 (TP) 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. For additional information, refer
to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic
Throttle Control Module/Description and Operation.
2-Track APP Sensor
Typical 2-Track APP Sensor
3-Track APP Sensor
There are three 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 three pedal position signals make sure the PCM
receives a correct input even if one 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 two reference voltage circuits, two signal
return circuits, and three signal circuits (a total of seven 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. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description
and Operation.
3-Track APP Sensor
Typical 3-Track APP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3567
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3568
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3569
Air Flow Meter/Sensor: Description and Operation
Engine Control Components
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 (TCC) 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 IAT sensor.
The hot wire electronic sensing element must be replaced as an assembly. Replacing only the
element may change the air flow calibration.
Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT
Sensor Wire Where Applicable) Terminals
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
Typical Mass Air Flow (MAF) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3570
Typical Drop-in Mass Air Flow (MAF) Sensor
Typical Drop-in Mass Air Flow (MAF) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3571
Air Flow Meter/Sensor: Service and Repair
Mass Air Flow (MAF) Sensor - 4.0L SOHC
Removal and Installation
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the 2 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 (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3575
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3576
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3577
Fuel Pressure Sensor/Switch: Description and Operation
Engine Control Components
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.
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3578
Fuel Pressure Sensor/Switch: Service and Repair
Fuel Rail Pressure and Temperature Sensor - 4.0L SOHC
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.
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.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Remove the intake manifold.
4. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
5. Remove the 2 bolts and the fuel rail pressure and temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. Remove and discard the O-ring seal.
7. NOTICE: Use an O-ring seal made of special fuel resistant material. Fuel will damage ordinary
O-ring seals and may cause the fuel
system to leak.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3579
NOTICE: Do not reuse the O-ring seal. The removal and installation process may damage the used
O-ring seals and cause the fuel system to leak.
To install, reverse the removal procedure.
- Lubricate the new O-ring seal with clean engine oil.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3583
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3584
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3585
Fuel Temperature Sensor: Description and Operation
Engine Control Components
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.
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3586
Fuel Temperature Sensor: Service and Repair
Fuel Rail Pressure and Temperature Sensor - 4.0L SOHC
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.
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.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or 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. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Remove the intake manifold.
4. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
5. Remove the 2 bolts and the fuel rail pressure and temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. Remove and discard the O-ring seal.
7. NOTICE: Use an O-ring seal made of special fuel resistant material. Fuel will damage ordinary
O-ring seals and may cause the fuel
system to leak.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3587
NOTICE: Do not reuse the O-ring seal. The removal and installation process may damage the used
O-ring seals and cause the fuel system to leak.
To install, reverse the removal procedure.
- Lubricate the new O-ring seal with clean engine oil.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3591
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3592
Inertia Fuel Shutoff Switch: Description and Operation
Engine Control Components
Inertia Fuel Shut-off (IFS) Switch
The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is
to shut off the fuel pump if a collision occurs. It consists of a steel cone held in place by a magnet.
When a sharp impact occurs, the cone 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.
Typical Inertia Fuel Shut-off (IFS) Switch
Typical Inertia Fuel Shut-off (IFS) Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3593
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.
NOTE: 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 2 bolts and the IFS switch.
- To install, tighten to 2 Nm (18 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer
Interest: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC P2135 Set
Throttle Position Sensor: Customer Interest A/C, Engine Controls - MIL ON/DTC P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer
Interest: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC P2135 Set > Page 3602
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC P2135 Set
Throttle Position Sensor: All Technical Service Bulletins A/C, Engine Controls - MIL ON/DTC
P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC P2135 Set > Page 3608
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 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 > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set >
Page 3614
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set >
Page 3615
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3620
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3621
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3622
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3623
^ 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3624
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3625
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3626
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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Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3627
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
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3628
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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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3629
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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Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3630
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade
> Page 3635
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.
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade
> Page 3636
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
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set >
Page 3642
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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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set >
Page 3643
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 > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3648
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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Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3649
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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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3650
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3651
^ 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3652
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3653
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3654
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3655
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3656
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3657
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 3658
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade
> Page 3663
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Throttle Position Sensor: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade
> Page 3664
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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3665
Throttle Position Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3666
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3667
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic
Throttle Body (ETB) Throttle Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle
Position Sensor
Engine Control Components
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. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description
and Operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic
Throttle Body (ETB) Throttle Position Sensor > Page 3670
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
Engine Control Components
Throttle Position (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, four operating conditions are determined by the
PCM from the TP. These 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
Typical TP Sensor
Typical TP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3671
Throttle Position Sensor: Service and Repair
Throttle Position (TP) Sensor
Removal
All vehicles
1. Remove the Air Cleaner (ACL) outlet pipe.
2. Disconnect the Throttle Position (TP) sensor electrical connector.
Vehicles equipped with a 4.6L (3V) engine
3. Disconnect the PCV hose from the heated PCV fitting.
4. Disconnect the heated PCV fitting electrical connector.
5. Remove the 2 bolts and the heated PCV fitting.
- Remove and discard the heated PCV fitting O-ring seal.
All vehicles
6. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts
because heat damage may occur. Damage
may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F).
NOTE: Do not use power tools.
Remove the TP sensor.
1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the
top TP sensor bolt ear reaches approximately
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3672
55°C (130°F), this should take no more than 3 minutes using a 1100-watt heat gun. The heat gun
should be about an 25.4 mm (1 in) away from the ETB.
2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature
measuring device, such as a digital temperature
laser or infrared thermometer, while heating the ETB.
3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard.
4. Using hand tools, remove the remaining bolt and discard.
5. Remove and discard the TP sensor.
Installation
All vehicles
1. NOTE: Do not use power tools.
Install the new TP sensor.
- Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in).
Vehicles equipped with a 4.6L (3V) engine
2. Install a new O-ring seal and position the heated PCV fitting and install the 2 bolts.
3. Connect the heated PCV fitting electrical connector.
4. Connect the PCV hose to the heated PCV fitting.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3673
All vehicles
5. Connect the TP sensor electrical connector.
6. Install the ACL outlet pipe.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service and Repair
Throttle Body: Service and Repair
Throttle Body
Removal and Installation
WARNING: Do not smoke, 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 Air Cleaner (ACL) outlet tube.
2. Disconnect the Throttle Body (TB) electrical connector.
3. Disconnect the Throttle Position (TP) sensor electrical connector.
4. Remove the nut and position the wiring harness bracket aside.
- To install, tighten to 9 Nm (80 lb-in).
5. Remove the 4 bolts, the TB and the gasket. Discard the gasket.
- To install, tighten to 9 Nm (80 lb-in).
6. To install, reverse the removal procedure.
- Install a new TB gasket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Customer Interest: > 09-22-4 > Nov > 09 > A/C, Engine Controls MIL ON/DTC P2135 Set
Throttle Position Sensor: Customer Interest A/C, Engine Controls - MIL ON/DTC P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Customer Interest: > 09-22-4 > Nov > 09 > A/C, Engine Controls MIL ON/DTC P2135 Set > Page 3685
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-22-4 > Nov > 09 > A/C, Engine
Controls - MIL ON/DTC P2135 Set
Throttle Position Sensor: All Technical Service Bulletins A/C, Engine Controls - MIL ON/DTC
P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-22-4 > Nov > 09 > A/C, Engine
Controls - MIL ON/DTC P2135 Set > Page 3691
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Page 3702
Throttle Position Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Page 3703
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Page 3704
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > Electronic Throttle Body (ETB) Throttle Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle
Position Sensor
Engine Control Components
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. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description
and Operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > Electronic Throttle Body (ETB) Throttle Position Sensor > Page 3707
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
Engine Control Components
Throttle Position (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, four operating conditions are determined by the
PCM from the TP. These 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
Typical TP Sensor
Typical TP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > Page 3708
Throttle Position Sensor: Service and Repair
Throttle Position (TP) Sensor
Removal
All vehicles
1. Remove the Air Cleaner (ACL) outlet pipe.
2. Disconnect the Throttle Position (TP) sensor electrical connector.
Vehicles equipped with a 4.6L (3V) engine
3. Disconnect the PCV hose from the heated PCV fitting.
4. Disconnect the heated PCV fitting electrical connector.
5. Remove the 2 bolts and the heated PCV fitting.
- Remove and discard the heated PCV fitting O-ring seal.
All vehicles
6. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts
because heat damage may occur. Damage
may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F).
NOTE: Do not use power tools.
Remove the TP sensor.
1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the
top TP sensor bolt ear reaches approximately
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > Page 3709
55°C (130°F), this should take no more than 3 minutes using a 1100-watt heat gun. The heat gun
should be about an 25.4 mm (1 in) away from the ETB.
2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature
measuring device, such as a digital temperature
laser or infrared thermometer, while heating the ETB.
3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard.
4. Using hand tools, remove the remaining bolt and discard.
5. Remove and discard the TP sensor.
Installation
All vehicles
1. NOTE: Do not use power tools.
Install the new TP sensor.
- Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in).
Vehicles equipped with a 4.6L (3V) engine
2. Install a new O-ring seal and position the heated PCV fitting and install the 2 bolts.
3. Connect the heated PCV fitting electrical connector.
4. Connect the PCV hose to the heated PCV fitting.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > Page 3710
All vehicles
5. Connect the TP sensor electrical connector.
6. Install the ACL outlet pipe.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
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. Failure to follow these
instructions may result in personal injury.
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 a calibrated RPM. The shutter is in the closed
position to prevent airflow blend from occurring in the intake manifold. The motorized unit is
energized above a calibrated RPM. The motorized unit is commanded on by the PCM initially at a
100 percent duty cycle to move the shutter to the open position, and then falling to approximately
50 percent to continue to hold the shutter open.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Firing Order: Specifications
Firing order...........................................................................................................................................
..................................................................1-4-2-5-3-6
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > System Information >
Specifications
Ignition Timing: Specifications
Base ignition timing................................................................................................................10
degrees Before Top Dead Center (BTDC), Non-adjustable
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Camshaft Position Sensor 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Camshaft Position Sensor 1 > Page 3726
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Camshaft Position Sensor 1 > Page 3727
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Camshaft Position Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Camshaft Position Sensor > Page 3730
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Camshaft Position Sensor > Page 3731
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Page 3732
Camshaft Position Sensor: Description and Operation
Engine Control Components
Camshaft Position (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 two CMP sensors are equipped with variable camshaft timing (VCT). The second
sensor is used to identify the position of the camshaft on bank 2.
There are two types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin
Hall-effect type sensor.
Typical Variable Reluctance CMP Sensor
Typical Variable Reluctance CMP Sensor
Typical Hall-effect CMP Sensor
Typical Hall-effect CMP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Page 3733
Camshaft Position Sensor: Service and Repair
Camshaft Position (CMP) Sensor - 4.0L SOHC
Removal and Installation
1. Disconnect the Camshaft Position (CMP) sensor electrical connector.
2. Remove the bolt and the CMP sensor.
- To install, tighten to 6 Nm (53 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations
Crankshaft Position Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 3737
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 3738
Crankshaft Position Sensor: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 3739
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 3740
Crankshaft Position Sensor: Description and Operation
Engine Control Components
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.
Typical Crankshaft Position (CKP) Sensor
Typical Crankshaft Position (CKP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 3741
Crankshaft Position Sensor: Service and Repair
Crankshaft Position (CKP) Sensor - 4.0L SOHC
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
3. Remove the 2 bolts and the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. NOTE: Be sure the sensor wiring is routed away from the battery cable.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service
and Repair
Ignition Cable: Service and Repair
Spark Plug Wires
Removal and Installation
1. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible
damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. For additional
information, refer to the Cylinder-to-Coil Terminal Relationship, Engine Ignition See: Description
and Operation in the Description and Operation.
Squeeze the locking tabs and twist while pulling upward to disconnect the 6 spark plug wires from
the ignition coil.
2. Detach the spark plug wires from the spark plug wire retainers.
3. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible
damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct spark plug.
With a twisting motion, use the Spark Plug Wire Remover to pull the spark plug wires from the
spark plugs.
4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3749
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3750
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3751
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3752
Ignition Coil: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3753
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3754
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3755
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3756
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3757
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3758
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Description and Operation > Coil on Plug (COP)
Ignition Coil: Description and Operation Coil on Plug (COP)
Engine Control Components
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). For additional information, refer to Ignition Systems See:
Description and Operation/Ignition Systems.
Typical Coil On Plug (COP)
Typical Coil On Plug (COP)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Description and Operation > Coil on Plug (COP) > Page 3761
Ignition Coil: Description and Operation Coil Pack
Engine Control Components
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 6-tower series 5 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.
Typical Four-Tower Coil Pack
Typical Four-Tower Coil Pack
Typical Six-Tower Coil Pack
Typical Six-Tower Coil Pack
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service
and Repair > Ignition Coil
Ignition Coil: Service and Repair Ignition Coil
Ignition Coil
Removal and Installation
1. Disconnect the ignition coil electrical connector.
2. Disconnect the radio noise suppressor electrical connector.
3. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible
damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. For additional
information, refer to the Cylinder-to-Coil Terminal Relationship, Engine Ignition See: Description
and Operation in the Description and Operation.
Squeeze the tabs and twist, while pulling upward to disconnect the 6 spark plug wires from the
ignition coil.
4. Remove the 4 bolts and the ignition coil.
- To install, tighten to 6 Nm (53 lb-in).
5. NOTE: Apply silicone dielectric compound to the inside of the ignition coil boots.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service
and Repair > Ignition Coil > Page 3764
Ignition Coil: Service and Repair Engine Ignition Components - Exploded View
Engine Ignition Components - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations
Knock Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 3768
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 3769
Knock Sensor: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 3770
Knock Sensor: Description and Operation
Engine Control Components
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.
Two Types of Knock Sensor (KS)
Two Types of Knock Sensor (KS)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 3771
Knock Sensor: Service and Repair
Knock Sensor (KS) - 4.0L SOHC
Removal and Installation
1. Remove the intake manifold.
2. Disconnect the Knock Sensor (KS) electrical connector.
3. Remove the bolt and the KS.
- To install, tighten to 20 Nm (177 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3777
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3778
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3781
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3782
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Page 3783
Camshaft Position Sensor: Description and Operation
Engine Control Components
Camshaft Position (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 two CMP sensors are equipped with variable camshaft timing (VCT). The second
sensor is used to identify the position of the camshaft on bank 2.
There are two types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin
Hall-effect type sensor.
Typical Variable Reluctance CMP Sensor
Typical Variable Reluctance CMP Sensor
Typical Hall-effect CMP Sensor
Typical Hall-effect CMP Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Page 3784
Camshaft Position Sensor: Service and Repair
Camshaft Position (CMP) Sensor - 4.0L SOHC
Removal and Installation
1. Disconnect the Camshaft Position (CMP) sensor electrical connector.
2. Remove the bolt and the CMP sensor.
- To install, tighten to 6 Nm (53 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 3788
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 3789
Crankshaft Position Sensor: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 3790
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 3791
Crankshaft Position Sensor: Description and Operation
Engine Control Components
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.
Typical Crankshaft Position (CKP) Sensor
Typical Crankshaft Position (CKP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 3792
Crankshaft Position Sensor: Service and Repair
Crankshaft Position (CKP) Sensor - 4.0L SOHC
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
3. Remove the 2 bolts and the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. NOTE: Be sure the sensor wiring is routed away from the battery cable.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Ignition Lock Cylinder - Functional
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.
NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a
new lock cylinder using the appropriate lock repair package. The lock repair package includes a
detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. With the ignition switch in the RUN position, press the locking pin with a suitable tool and remove
the ignition lock cylinder.
2. If a new lock cylinder with keys is replaced, the new Passive Anti-Theft System (PATS) keys
must be programmed.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
> Page 3798
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Ignition Lock Cylinder - Non Functional
Removal
1. Remove the Passive Anti-Theft System (PATS) transceiver.
2. Remove the ignition lock cylinder.
- Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
- Use a 3/8-inch diameter drill bit to drill down the middle of the ignition lock key slot until the
ignition lock cylinder breaks loose.
- Remove and discard the ignition lock cylinder and drill shavings from the steering column.
3. Remove the bearing retainer.
4. Remove the steering column lock housing bearing and steering column lock gear.
Installation
1. Thoroughly clean all drill shavings from the steering column and inspect it for damage.
2. Install a new ignition lock cylinder.
- Verify the ignition lock cylinder operation.
3. Program the new PATS keys.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations
Knock Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations > Page 3802
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations > Page 3803
Knock Sensor: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations > Page 3804
Knock Sensor: Description and Operation
Engine Control Components
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.
Two Types of Knock Sensor (KS)
Two Types of Knock Sensor (KS)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations > Page 3805
Knock Sensor: Service and Repair
Knock Sensor (KS) - 4.0L SOHC
Removal and Installation
1. Remove the intake manifold.
2. Disconnect the Knock Sensor (KS) electrical connector.
3. Remove the bolt and the KS.
- To install, tighten to 20 Nm (177 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Gap
Spark Plug: Specifications Gap
Item.......................................................................................................................................................
...............................................................Specification
Spark Plug Gap....................................................................................................................................
....................................1.32-1.42 mm (0.052-0.056 in)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Gap > Page 3810
Spark Plug: Specifications Torque Specifications
Spark plugs...........................................................................................................................................
........................................................17 Nm (150 lb-in)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3811
Spark Plug: Application and ID
Item.......................................................................................................................................................
...............................................................Specification
Spark Plug type....................................................................................................................................
....................................................................AGSF24N
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3812
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.
- Install a new 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.
5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine
damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized
installation of a heli-coil insert in place of the spark plug threads. Install a new spark plug.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3813
6. Inspect for overheating, identified by white or light gray spots and 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service
and Repair > Engine Ignition Components - Exploded View
Spark Plug: Service and Repair Engine Ignition Components - Exploded View
Engine Ignition Components - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service
and Repair > Engine Ignition Components - Exploded View > Page 3816
Spark Plug: Service and Repair Spark Plugs
Spark Plugs
Removal and Installation
1. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible
damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct spark plug. Refer to the Cylinder-to-Coil
Terminal Relationship, Engine Ignition See: Description and Operation in the Description and
Operation.
With a twisting motion, use the Spark Plug Wire Remover to pull the spark plug wire from the spark
plug.
2. NOTE: Use compressed air to remove any foreign material from the spark plug wells before
removing the spark plugs.
Remove the spark plugs.
- To install, tighten to 17 Nm (150 lb-in).
3. Use a suitable spark plug gap tool to check and adjust the spark plug gap.
4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal
1. Remove the front floor console.
2. Disconnect the Brake Shift Interlock Actuator (BSIA) electrical connector.
3. Remove the screw and the BSIA.
Installation
1. Install the BSIA and the screw.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3823
2. Connect the BSIA electrical connector.
3. Install the front floor console.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
Transmission Control Indicator Lamp (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
Customer Interest for Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
Customer Interest for Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift >
Page 3839
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
Customer Interest for Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift >
Page 3840
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh
1-2 Shift
Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2
Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh
1-2 Shift > Page 3846
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh
1-2 Shift > Page 3847
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Description
and Operation
Brake Switch - TCC: Description and Operation
Engine Control Components
Brake Pedal Position (BPP) Switch
The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal
to the PCM indicating the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Typical BPP Switch
Typical BPP Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Description and Operation
Transmission Mode Switch: Description and Operation
Engine Control Components
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.
Typical Transmission Control Switch (TCS) (Column Shift)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS) (Floor Shift)
Typical Transmission Control Switch (TCS)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 >
Service and Repair > Transmission Control Switch (TCS)
Transmission Mode Switch: Service and Repair Transmission Control Switch (TCS)
External Controls
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) is a momentary contact switch located on the selector
lever knob. Pushing the TCS will either disengage or engage the overdrive function of the
transmission. If OVERDRIVE is disengaged, the message Overdrive (O/D) OFF will illuminate on
the Instrument Cluster (IC).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 >
Service and Repair > Transmission Control Switch (TCS) > Page 3858
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch
Transmission Control (TC) Switch
Removal
1. Remove the selector lever knob. For additional information, refer to Selector Lever Knob See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Shifter A/T/Service and Repair/Selector Lever Knob.
2. Remove the Transmission Control Switch (TCS) from the knob.
Installation
1. Install the TCS into the selector lever knob.
2. Install the selector lever knob. For additional information, refer to Selector Lever Knob See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Shifter A/T/Service and Repair/Selector Lever Knob.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3862
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3863
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3864
Transmission Position Switch/Sensor: Adjustments
5R55S
Transmission Range (TR) Sensor Adjustment
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 Transmission Range (TR) sensor connector.
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable end from the manual control lever.
6. Remove the manual control lever nut and the manual control lever.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3865
7. Loosen but do not remove the TR sensor screws.
8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence.
- Tighten to 8 Nm (71 lb-in).
9. Install the manual control lever and manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
11. Reconnect the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3866
12. Reinstall the rubber boot over the TR 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 (V6-4.0L (2009))
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 3867
Transmission Position Switch/Sensor: Service and Repair
5R55S
Digital Transmission Range (TR) Sensor
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
3. Move the TR sensor connector boot back to gain access to the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3868
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable from the manual control lever.
6. Remove the manual control lever nut.
7. Remove the TR sensor.
Installation
1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to
prevent damage to the sensor.
Install the TR sensor and loosely install the TR sensor screw and washer (2 required).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3869
2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual control lever must be in the NEUTRAL position.
Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence. Tighten to 8 Nm (71 lb-in).
3. Install the manual control lever and the manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
5. Connect the TR sensor connector.
6. Move the TR sensor connector boot back over the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3870
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 (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3875
Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3876
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3877
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Output Shaft Speed (OSS) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Output Shaft Speed (OSS) Sensor > Page 3880
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Output Shaft Speed (OSS) Sensor > Page 3881
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3884
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the Turbine Shaft Speed (TSS) sensor 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3885
Installation
All vehicles
1. Inspect the TSS O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the TSS sensor connector.
3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever bracket and selector lever bracket screws.
- Tighten to 40 Nm (30 lb-ft).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3886
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3887
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3888
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
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 connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3889
9. Remove the OSS sensor.
1. Remove the OSS sensor screw.
2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
All vehicles
1. Inspect the OSS O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the OSS sensor connector.
3. Connect the HO2S connector to the transmission case.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3890
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever cable bracket and selector lever cable bracket
screws.
- 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.
7. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
8. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3891
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3892
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3893
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the intermediate shaft speed sensor 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 (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3894
Installation
All vehicles
1. Inspect the O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the intermediate shaft speed sensor connector.
3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever cable bracket and selector lever cable bracket
screws.
- Tighten to 40 Nm (30 lb-ft).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3895
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift
PROM - Programmable Read Only Memory: Customer Interest Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift > Page 3904
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift > Page 3905
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift > Page 3911
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift > Page 3912
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-21-2 > Oct > 08 > Computers/Controls Sync Software Programming > Page 3917
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-21-2 > Oct > 08 > Computers/Controls Sync Software Programming > Page 3918
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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Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-21-2 > Oct > 08 > Computers/Controls Sync Software Programming > Page 3919
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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Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-21-2 > Oct > 08 > Computers/Controls Sync Software Programming > Page 3920
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)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-21-2 > Oct > 08 > Computers/Controls Sync Software Programming > Page 3921
^ 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 (V6-4.0L (2009))
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: >
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 (V6-4.0L (2009))
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: >
09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 3927
^ 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 (V6-4.0L (2009))
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: >
09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 3928
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 (V6-4.0L (2009))
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: >
09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 3934
^ 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 (V6-4.0L (2009))
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: >
09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 3935
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 (V6-4.0L (2009))
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
Removal
1. Remove the front floor console.
2. Disconnect the Brake Shift Interlock Actuator (BSIA) electrical connector.
3. Remove the screw and the BSIA.
Installation
1. Install the BSIA and the screw.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3942
2. Connect the BSIA electrical connector.
3. Install the front floor console.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal
1. Remove the front floor console.
2. Disconnect the Brake Shift Interlock Actuator (BSIA) electrical connector.
3. Remove the screw and the BSIA.
Installation
1. Install the BSIA and the screw.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 3948
2. Connect the BSIA electrical connector.
3. Install the front floor console.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 09-12-12 > Jun > 09 > A/T - Loss Of
2nd/3rd/5th Gears/Ratio DTC's Set
Band Apply Servo: Customer Interest A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
TSB 09-12-12
06/29/09
5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH
GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN
BORE WEAR
FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport
Trac
LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator
MERCURY: 2002-2009 Mountaineer
ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006
Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped
with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd,
3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case
bore wear causing reduced apply pressure.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
For transmissions that have been determined to require an overhaul or rebuild and the overdrive
band or intermediate band have excessive wear or burned/damaged band friction material, the
cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles,
usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes
worse when hot. (Figure 1)
In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore
located closest to the bell housing. When we refer to the intermediate bore, we are talking about
the larger bore located next to the line pressure tap.
Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool
5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 09-12-12 > Jun > 09 > A/T - Loss Of
2nd/3rd/5th Gears/Ratio DTC's Set > Page 3957
1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the
case with the servo's snap-ring. (Figure 2)
2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use,
as long as one of the lands is under the 3/8" Allen
screw.
NOTE
CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES,
PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE.
3. Ream out the bore using the 9/16" reamer applying ample lubrication.
NOTE
DO NOT REAM ABOVE 500 RPM. (Figure 3)
4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer.
5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too
hard on the reamer or turn the reamer faster than
500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 09-12-12 > Jun > 09 > A/T - Loss Of
2nd/3rd/5th Gears/Ratio DTC's Set > Page 3958
a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the
bushing's hat. (Figure 4A)
b. Overdrive servo bushing. (Figure 4B)
c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the
valve body).
7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive
the bushing in by hitting the driver until the bushing
bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut
in the handle.
8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following
the servo apply holes in the case 5R555 case
shown.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 09-12-12 > Jun > 09 > A/T - Loss Of
2nd/3rd/5th Gears/Ratio DTC's Set > Page 3959
a. Overdrive servo. (Figure 6)
b. Intermediate servo. (Figure 7)
NOTE
FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO
SHIFT CONDITION.
9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing
with a rubber mallet. Once the pin is inside the bushing,
use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 09-12-12 > Jun > 09 > A/T - Loss Of
2nd/3rd/5th Gears/Ratio DTC's Set > Page 3960
Correctly installed bushings will be flush inside of case. (Figure 9)
The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the
cutting edges to help provide optimum bushing installation and increased tool life.
After bushing installation, thoroughly wash the case before rebuilding transmission.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-12-12 > Jun > 09 > A/T - Loss
Of 2nd/3rd/5th Gears/Ratio DTC's Set
Band Apply Servo: All Technical Service Bulletins A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
TSB 09-12-12
06/29/09
5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH
GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN
BORE WEAR
FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport
Trac
LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator
MERCURY: 2002-2009 Mountaineer
ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006
Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped
with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd,
3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case
bore wear causing reduced apply pressure.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
For transmissions that have been determined to require an overhaul or rebuild and the overdrive
band or intermediate band have excessive wear or burned/damaged band friction material, the
cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles,
usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes
worse when hot. (Figure 1)
In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore
located closest to the bell housing. When we refer to the intermediate bore, we are talking about
the larger bore located next to the line pressure tap.
Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool
5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-12-12 > Jun > 09 > A/T - Loss
Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 3966
1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the
case with the servo's snap-ring. (Figure 2)
2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use,
as long as one of the lands is under the 3/8" Allen
screw.
NOTE
CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES,
PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE.
3. Ream out the bore using the 9/16" reamer applying ample lubrication.
NOTE
DO NOT REAM ABOVE 500 RPM. (Figure 3)
4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer.
5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too
hard on the reamer or turn the reamer faster than
500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-12-12 > Jun > 09 > A/T - Loss
Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 3967
a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the
bushing's hat. (Figure 4A)
b. Overdrive servo bushing. (Figure 4B)
c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the
valve body).
7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive
the bushing in by hitting the driver until the bushing
bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut
in the handle.
8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following
the servo apply holes in the case 5R555 case
shown.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-12-12 > Jun > 09 > A/T - Loss
Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 3968
a. Overdrive servo. (Figure 6)
b. Intermediate servo. (Figure 7)
NOTE
FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO
SHIFT CONDITION.
9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing
with a rubber mallet. Once the pin is inside the bushing,
use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-12-12 > Jun > 09 > A/T - Loss
Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 3969
Correctly installed bushings will be flush inside of case. (Figure 9)
The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the
cutting edges to help provide optimum bushing installation and increased tool life.
After bushing installation, thoroughly wash the case before rebuilding transmission.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Band Apply Servo: > 09-21-7 > Nov >
09 > Instruments - Trip Odometers/Fuel Economy Resets
Fuel Distance/Mileage Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel
Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Band Apply Servo: > 09-21-7 > Nov >
09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 3975
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Band Apply Servo: > 09-21-7 > Nov >
09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 3981
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Description and Operation
Brake Switch - TCC: Description and Operation
Engine Control Components
Brake Pedal Position (BPP) Switch
The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal
to the PCM indicating the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Typical BPP Switch
Typical BPP Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set
Case: Customer Interest A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
TSB 09-12-12
06/29/09
5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH
GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN
BORE WEAR
FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport
Trac
LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator
MERCURY: 2002-2009 Mountaineer
ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006
Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped
with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd,
3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case
bore wear causing reduced apply pressure.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
For transmissions that have been determined to require an overhaul or rebuild and the overdrive
band or intermediate band have excessive wear or burned/damaged band friction material, the
cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles,
usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes
worse when hot. (Figure 1)
In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore
located closest to the bell housing. When we refer to the intermediate bore, we are talking about
the larger bore located next to the line pressure tap.
Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool
5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3993
1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the
case with the servo's snap-ring. (Figure 2)
2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use,
as long as one of the lands is under the 3/8" Allen
screw.
NOTE
CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES,
PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE.
3. Ream out the bore using the 9/16" reamer applying ample lubrication.
NOTE
DO NOT REAM ABOVE 500 RPM. (Figure 3)
4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer.
5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too
hard on the reamer or turn the reamer faster than
500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3994
a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the
bushing's hat. (Figure 4A)
b. Overdrive servo bushing. (Figure 4B)
c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the
valve body).
7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive
the bushing in by hitting the driver until the bushing
bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut
in the handle.
8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following
the servo apply holes in the case 5R555 case
shown.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3995
a. Overdrive servo. (Figure 6)
b. Intermediate servo. (Figure 7)
NOTE
FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO
SHIFT CONDITION.
9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing
with a rubber mallet. Once the pin is inside the bushing,
use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 3996
Correctly installed bushings will be flush inside of case. (Figure 9)
The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the
cutting edges to help provide optimum bushing installation and increased tool life.
After bushing installation, thoroughly wash the case before rebuilding transmission.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of
2nd/3rd/5th Gears/Ratio DTC's Set
Case: All Technical Service Bulletins A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
TSB 09-12-12
06/29/09
5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH
GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN
BORE WEAR
FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport
Trac
LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator
MERCURY: 2002-2009 Mountaineer
ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006
Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped
with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd,
3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case
bore wear causing reduced apply pressure.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
For transmissions that have been determined to require an overhaul or rebuild and the overdrive
band or intermediate band have excessive wear or burned/damaged band friction material, the
cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles,
usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes
worse when hot. (Figure 1)
In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore
located closest to the bell housing. When we refer to the intermediate bore, we are talking about
the larger bore located next to the line pressure tap.
Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool
5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4002
1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the
case with the servo's snap-ring. (Figure 2)
2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use,
as long as one of the lands is under the 3/8" Allen
screw.
NOTE
CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES,
PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE.
3. Ream out the bore using the 9/16" reamer applying ample lubrication.
NOTE
DO NOT REAM ABOVE 500 RPM. (Figure 3)
4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer.
5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too
hard on the reamer or turn the reamer faster than
500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4003
a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the
bushing's hat. (Figure 4A)
b. Overdrive servo bushing. (Figure 4B)
c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the
valve body).
7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive
the bushing in by hitting the driver until the bushing
bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut
in the handle.
8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following
the servo apply holes in the case 5R555 case
shown.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4004
a. Overdrive servo. (Figure 6)
b. Intermediate servo. (Figure 7)
NOTE
FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO
SHIFT CONDITION.
9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing
with a rubber mallet. Once the pin is inside the bushing,
use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4005
Correctly installed bushings will be flush inside of case. (Figure 9)
The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the
cutting edges to help provide optimum bushing installation and increased tool life.
After bushing installation, thoroughly wash the case before rebuilding transmission.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 09-18-10 > Sep > 09 >
Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 09-18-10 > Sep > 09 >
Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4014
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 09-18-10 > Sep > 09 >
Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4015
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep
> 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2
Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep
> 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4021
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep
> 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4022
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications
Automatic Tranmission Fluid Capacity
5R55 ....................................................................................................................................................
............................................... 11.2 Quarts ( 1067 L )
6R80 ....................................................................................................................................................
................................................ 11.2 Quarts ( 10.6 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications > Page 4027
Fluid - A/T: Fluid Type Specifications
5R55S ..................................................................................................................................................
................................... Motorcraft MERCON V ATF
6R80 ....................................................................................................................................................
.................................. Motorcraft MERCON SP ATF
Use of a duel usage fluid in an automatic transmission requiring MERCON V may cause
transmission damage. Use of any fluid other than the recommended fluid may cause transmission
damage. Refer to scheduled maintenance information to determine the correct service interval.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S
Fluid - A/T: Service and Repair 5R55S
Transmission Fluid Level Check
Transmission Fluid Level Check
Transmission Fluid Fill Reference
NOTE: Left side of case shown.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S > Page 4030
1. Using the scan tool, monitor the Transmission Fluid Temperature (TFT).
2. Start the engine.
3. NOTE: Engine idle speed is approximately 650 rpm.
Run the engine until the TFT is between 27-49°C (80-120°F).
4. Move the 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.
8. Install the Fluid Level and Fill Plug Adapter into the pan.
9. NOTE: Prior to filling the Fluid Transporter/Evacuator/Injector with transmission fluid, make sure
that the canister is clean.
Fill the Fluid Transporter/Evacuator/Injector with transmission fluid.
10. Hang the Fluid Transporter/Evacuator/Injector under the vehicle. Position it upright and close to
the transmission.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S > Page 4031
11. Connect the Fluid Transporter/Evacuator/Injector.
- 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 Rubber Tip Air Nozzle. Transmission fluid will
immediately start flowing out of the Fluid Transporter/Evacuator/Injector 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 Rubber Tip
Air Nozzle from the end of the hose.
14. Inspect the transmission fluid level in the Fluid Transporter/Evacuator/Injector. 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 Vacuum Pump Kit on the open end of the
vacuum/pressure hose on the Fluid Transporter/Evacuator/Injector
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 TFT 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.
17. Reinstall the small (center) transmission fluid level indicating plug.
- Tighten to 10 Nm (89 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S > Page 4032
18. Check the operation of the transmission by moving the selector lever slowly through each gear,
stopping in each position and allowing the
transmission to engage.
Transmission Fluid Exchange
Transmission Fluid Exchange
NOTICE: Use transmission fluid specific for this transmission. Do not use any supplemental
transmission fluid additives or cleaning agents. The use of these products can cause internal
transmission components to fail, which will affect the operation of the transmission.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Use the Heavy-Duty Transmission and Power Steering Fluid X-Changer to change the fluid.
3. Connect the Heavy-Duty Transmission and Power Steering Fluid X-Changer to the transmission
fluid cooler tube after the transmission fluid
cooler on the return tube. This will help remove any foreign material trapped in the transmission
fluid coolers.
4. Perform the transmission fluid exchange using the Heavy-Duty Transmission and Power
Steering Fluid X-Changer. Follow the manufacturer's
instructions included with the machine.
5. Once the transmission fluid exchange is completed, disconnect the Heavy-Duty Transmission
and Power Steering Fluid X-Changer. Reconnect any
disconnected transmission fluid cooler tubes.
6. Using the scan tool with the engine running, check and make sure that the transmission is at
normal operating temperature 66-77°C (150-170°F).
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.
Transmission Fluid Drain and Refill
Transmission Fluid Drain and Refill
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S > Page 4033
Fluid Fill Reference
NOTE: Left side of case shown.
Draining
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S > Page 4034
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 transmission fluid to drain.
Refill
1. Install the transmission fluid drain plug.
- Tighten to 26 Nm (19 lb-ft).
2. Hold the larger transmission fluid drain plug with a wrench and remove the small (center)
transmission fluid level indicating plug.
3. Install the Fluid Level and Fill Plug Adapter into the transmission fluid pan.
4. NOTE: Prior to filling the Fluid Transporter/Evacuator/Injector with transmission fluid, make sure
that the canister is clean.
Fill the Fluid Transporter/Evacuator/Injector with transmission fluid.
5. Hang the Fluid Transporter/Evacuator/Injector under the vehicle, upright and close to the
transmission.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S > Page 4035
6. Connect the Fluid Transporter/Evacuator/Injector.
- 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
Rubber Tip Air Nozzle. Transmission fluid will
immediately start flowing out of the Fluid Transporter/Evacuator/Injector into the transmission fluid
pan.
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 Rubber Tip 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 (TFT) is
between 27°C-49°C (80°F-120°F).
10. Inspect the transmission fluid level in the Fluid Transporter/Evacuator/Injector. 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 Kit on the open end of the
vacuum/pressure hose on the Fluid
Transporter/Evacuator/Injector 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S > Page 4036
13. Reinstall the small (center) transmission fluid level indicating plug.
- Tighten to 10 Nm (89 lb-in).
Transmission Fluid Cooler Backflushing and Cleaning
Transmission Fluid Cooler Backflushing and Cleaning
NOTICE: 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.
NOTICE: 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 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 tubes, connect 2 additional rubber
hoses to the transmission end of the steel
transmission cooler tubes as described. 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 tubes (blow air into the transmission cooler
return tube) until all the fluid is removed.
7. Remove the rubber return hose from the remaining steel cooler tube.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S > Page 4037
Fluid - A/T: Service and Repair 6R80
Transmission Fluid Drain and Refill
Transmission Fluid Drain and Refill
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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S > Page 4038
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.
5. Install the transmission fluid pan and tighten the bolts in a crisscross pattern.
- Tighten to 12 Nm (106 lb-in).
Transmission Fluid Refill
NOTICE: 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.
NOTICE: The vehicle should not be driven if the transmission fluid level is low as internal failure
could result.
NOTICE: The transmission fluid fill plug is located near the exhaust system. The exhaust will be
extremely hot during this procedure.
NOTICE: 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 transmission fluid to the transmission is an initial fill enabling you to start
the engine.
- The cold 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 fill 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 transmission fluid added to the transmission
as an initial fill if:
- the transmission has been overhauled.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S > Page 4039
- a new mechatronic assembly has been installed.
- the transmission fluid pan or transmission fluid filter have been removed.
Using the Transmission Fluid Fill Tube, add 3.3L (3.5 qt) of transmission fluid to the transmission
through the transmission fluid fill hole. For additional information, refer to Adding Additional
Transmission Fluid in this procedure.
2. Check the transmission fluid level cold.
- The vehicle is safe to drive if the transmission fluid is in the cold level range 32°C-43°C
(90°F-110°F).
- Using the scan tool and with the engine running, place the selector lever in each gear position
and hold approximately 5 seconds. Place the 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.
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 transmission fluid to the cold level location as shown in the illustration.
6. Install the transmission fluid fill plug.
- Tighten to 35 Nm (26 lb-ft).
7. While driving the vehicle, use the scan tool to verify that the Transmission Fluid Temperature
(TFT) 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 transmission fluid cooling system. With the engine idling (600-750 rpm) in PARK, verify that the TFT 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S > Page 4040
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.
11. Using the scan tool verify that the TFT 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 Transmission Fluid Fill Tube into the transmission fluid fill hole.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S > Page 4041
2. Fill the Transporter Fluid Evacuator/Injector with approximately 0.47L (1 pt) of transmission fluid.
3. Hang the Transporter Fluid Evacuator/Injector under the vehicle, upright and close to the
transmission.
4. Connect the Transporter Fluid Evacuator/Injector and Transmission Fluid Fill Tube.
- Connect the open end of the fluid hose from the Transporter Fluid Evacuator/Injector onto the
Transmission Fluid Fill Tube from the transmission case.
5. Use a Rubber Tip Air Nozzle to apply a maximum of 206.85 kPa (30 psi) to the open end of the
vacuum/pressure hose from the Transporter Fluid
Evacuator/Injector. Transmission fluid will immediately start flowing out of the Transporter Fluid
Evacuator/Injector 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S > Page 4042
7. Using the scan tool, verify that the TFT 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).
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
Transporter Fluid Evacuator/Injector and the
Vacuum Pump Kit to extract any excessive transmission fluid.
2. Using the scan tool, verify that the TFT 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S > Page 4043
Transmission Fluid Exchange
Transmission Fluid Exchange
NOTICE: Use transmission fluid specific for this transmission. Do not use any supplemental
transmission fluid additives or cleaning agents. The use of these products can cause internal
transmission components to fail, which will affect the operation of the transmission.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Use the Heavy-Duty Transmission and Power Steering Fluid X-Changer to change the fluid.
3. Connect the Heavy-Duty Transmission and Power Steering Fluid X-Changer to the transmission
fluid cooler tube after the transmission fluid
cooler on the return tube. This will help remove any foreign material trapped in the transmission
fluid coolers.
4. Perform the transmission fluid exchange using the Heavy-Duty Transmission and Power
Steering Fluid X-Changer. Follow the manufacturer's
instructions included with the machine.
5. Once the transmission fluid exchange is completed, disconnect the Heavy-Duty Transmission
and Power Steering Fluid X-Changer. Reconnect any
disconnected transmission fluid cooler tubes.
6. Using the scan tool with the engine running, check and make sure that the transmission is at
normal operating temperature 66-77°C (150-170°F).
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.
Transmission Fluid Level Check
Transmission Fluid Level Check
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S > Page 4044
NOTICE: The vehicle should not be driven if the transmission fluid level is low as internal failure
could result.
NOTICE: 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 or transmission fluid cooler tubes has
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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S > Page 4045
6. Using the scan tool, verify that the Transmission Fluid Temperature (TFT) 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. For additional information, refer to Transmission Fluid Drain and Refill See: Service and
Repair/Procedures/6R80/Transmission Fluid Drain and Refill.
Install the transmission fluid fill plug. Tighten to 35 Nm (26 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S
Fluid Filter - A/T: Service and Repair 5R55S
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 pan drain plug and drain the transmission fluid.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S > Page 4050
5. Remove and discard the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet.
Installation
1. NOTICE: Damage may occur to transmission fluid filter seals if they are not lubricated with
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 filter.
- Tighten to 10 Nm (89 lb-in).
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S > Page 4051
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 (97 lb-in).
6. Install the transmission fluid pan drain plug.
- Tighten to 26 Nm (19 lb-ft).
7. Partially fill the transmission. For additional information, refer to Transmission Fluid Exchange
See: Service and
Repair/Procedures/5R55S/Transmission Fluid Exchange or Transmission Fluid Drain and Refill
See: Service and Repair/Procedures/5R55S/Transmission Fluid Drain and Refill.
Transmission Filter - In Line
Transmission Filter - In Line
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S > Page 4052
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.
3. Using the Transmission Disconnect Tool, disconnect the transmission fluid cooler connector.
4. Remove the section of the transmission fluid cooler tube at the second flare.
- Clean and de-burr 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 one and one-half turns to seat
the ferrule in the connector.
6. Remove the section of the transmission fluid cooler hose as illustrated.
7. NOTICE: 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 tube with the red arrow on the transmission fluid filter pointing
away from the transmission fluid cooler and toward the transmission (the transmission fluid return
tube 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.
NOTICE: Do not install any transmission fluid cooler hoses or transmission fluid cooler tubes with a
bend entering the transmission fluid
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S > Page 4053
filter greater than 60 degrees. Doing so can block transmission fluid flow and cause internal
transmission damage.
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 transmission fluid.
- Verify for correct operation.
- Check the filter for leaks.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S > Page 4054
Fluid Filter - A/T: Service and Repair 6R80
Fluid Pan, Gasket and Filter
Removal
NOTICE: The use of any transmission fluid other 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 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. Remove the transmission fluid pan gasket.
5. Remove and discard the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S > Page 4055
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 seal is in the case,
carefully remove the seal without scratching the case.
2. Make sure that the seal is on the transmission fluid filter and lubricate the seal with automatic
transmission fluid.
3. NOTE: The transmission fluid filter may be reused if no excessive contamination is indicated.
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.
Install a new transmission fluid pan gasket if required.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S > Page 4056
6. Install the transmission fluid pan and tighten the bolts in a crisscross pattern.
- Tighten to 12 Nm (106 lb-in).
7. Using the Adding Additional Transmission Fluid procedure, fill and check the transmission fluid.
For additional information, refer to Transmission
Fluid Drain and Refill See: Service and Repair/Procedures/6R80/Transmission Fluid Drain and
Refill.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications > 5R55S
Fluid Pan: Specifications 5R55S
Tighten the transmission fluid pan screws in a crisscross sequence. Tighten to.................................
..............................................................................................................................................................
.......11 Nm (97 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications > 5R55S > Page 4061
Fluid Pan: Specifications 6R80
Install the transmission fluid pan and tighten the bolts in a crisscross pattern. Tighten to...................
..............................................................................................................................................................
...................12 Nm (106 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > 5R55S
Fluid Pan: Service and Repair 5R55S
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 pan drain plug and drain the transmission fluid.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > 5R55S > Page 4064
5. Remove and discard the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet.
Installation
1. NOTICE: Damage may occur to transmission fluid filter seals if they are not lubricated with
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 filter.
- Tighten to 10 Nm (89 lb-in).
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > 5R55S > Page 4065
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 (97 lb-in).
6. Install the transmission fluid pan drain plug.
- Tighten to 26 Nm (19 lb-ft).
7. Partially fill the transmission. For additional information, refer to Transmission Fluid Exchange
See: Service and
Repair/Procedures/5R55S/Transmission Fluid Exchange or Transmission Fluid Drain and Refill
See: Service and Repair/Procedures/5R55S/Transmission Fluid Drain and Refill.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > 5R55S > Page 4066
Fluid Pan: Service and Repair 6R80
Fluid Pan, Gasket and Filter
Removal
NOTICE: The use of any transmission fluid other 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 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. Remove the transmission fluid pan gasket.
5. Remove and discard the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > 5R55S > Page 4067
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 seal is in the case,
carefully remove the seal without scratching the case.
2. Make sure that the seal is on the transmission fluid filter and lubricate the seal with automatic
transmission fluid.
3. NOTE: The transmission fluid filter may be reused if no excessive contamination is indicated.
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.
Install a new transmission fluid pan gasket if required.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > 5R55S > Page 4068
6. Install the transmission fluid pan and tighten the bolts in a crisscross pattern.
- Tighten to 12 Nm (106 lb-in).
7. Using the Adding Additional Transmission Fluid procedure, fill and check the transmission fluid.
For additional information, refer to Transmission
Fluid Drain and Refill See: Service and Repair/Procedures/6R80/Transmission Fluid Drain and
Refill.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
Transmission Control Indicator Lamp (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: >
09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: >
09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4082
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: >
09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4083
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2
Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
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Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4089
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4090
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S
Seals and Gaskets: Service and Repair 5R55S
Extension Housing Seal
Extension Housing Seal - Rear Wheel Drive (RWD)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the driveshaft.
3. Using the Torque Converter Fluid Seal Remover and Slide Hammer, remove the extension
housing seal.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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System Information > Service and Repair > 5R55S > Page 4095
Installation
1. NOTE: Make sure the extension housing seal is correctly installed onto the Transmission
Extension Housing Oil Seal Installer and the garter
spring is in the correct position.
Using the Transmission Extension Housing Oil Seal Installer, install the extension housing seal.
2. Install the driveshaft.
3. Carry out the transmission fluid level check. For additional information, refer to Transmission
Fluid Level Check See: Service and
Repair/Procedures/5R55S/Transmission Fluid Level Check.
Extension Housing Gasket
Extension Housing Gasket - Rear Wheel Drive (RWD)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
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System Information > Service and Repair > 5R55S > Page 4096
2. Remove the driveshaft.
3. Support the transmission with a suitable jack.
4. Remove the transmission support insulator-to-crossmember nuts.
5. Remove the transmission support insulator-to-extension housing screws.
6. Raise the transmission and remove the transmission support insulator.
7. NOTE: The park pawl, park pawl return spring and park pawl shaft may fall out during removal of
the extension housing.
Remove the extension housing screws and the extension housing.
8. Remove and discard the extension housing gasket.
Installation
1. Clean the extension housing and install a new extension housing gasket. Verify that the park
pawl is installed correctly.
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System Information > Service and Repair > 5R55S > Page 4097
2. NOTE: Verify the park lever actuating rod is correctly seated into the case parking rod guide cup.
Install the extension housing and the extension housing screws.
- Tighten to 30 Nm (22 lb-ft).
3. Install the transmission support insulator and lower the transmission onto the transmission
support insulator.
4. Install the transmission support insulator-to-extension housing screws.
- Tighten to 90 Nm (66 lb-ft).
5. Install the transmission support insulator-to-crossmember nuts.
- Tighten to 90 Nm (66 lb-ft).
6. Install the driveshaft.
7. Carry out the transmission fluid level check. For additional information, refer to Transmission
Fluid Level Check See: Service and
Repair/Procedures/5R55S/Transmission Fluid Level Check.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S > Page 4098
Seals and Gaskets: Service and Repair 6R80
Output Shaft Seal
Output Shaft Seal
NOTE: Rear Wheel Drive (RWD) shown, Four-Wheel Drive (4WD) similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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System Information > Service and Repair > 5R55S > Page 4099
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 nut, remove the stake to prevent
damage to the output shaft.
Remove and discard the output shaft flange nut.
4. Remove the extension housing flange seal and the output shaft flange.
5. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the output shaft seal.
6. Remove the slip plane washer.
Four-Wheel Drive (4WD) vehicles
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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System Information > Service and Repair > 5R55S > Page 4100
7. Remove the transfer case.
8. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the output shaft seal.
Installation
RWD vehicles
1. Install the slip plane washer.
2. Position a new output shaft seal.
3. Using the 6R80 Rear Seal 4X2 Installer, install the output shaft seal.
4. Install the output shaft flange.
5. Install the extension housing flange seal and a new output shaft flange nut.
- Tighten to 80 Nm (59 lb-ft).
- After installing the new output shaft flange nut, it must be staked at the slots to prevent it from
coming loose.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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System Information > Service and Repair > 5R55S > Page 4101
6. Install the rear driveshaft.
4WD vehicles
7. Position the output shaft seal.
8. Using the 6R80 Rear Seal 4X4 Installer, install a new output shaft seal.
9. Install the transfer case.
All vehicles
10. Fill and check the transmission fluid. For additional information, refer to Transmission Fluid
Level Check See: Service and
Repair/Procedures/6R80/Transmission Fluid Level Check.
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 heat shield.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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System Information > Service and Repair > 5R55S > Page 4102
3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Move the locking tab up and disconnect the transmission selector lever cable end from the manual
control lever ball stud.
1. Locking tab.
2. Selector lever cable end.
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 aid in allowing 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.
7. Remove the transmission fluid pan gasket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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System Information > Service and Repair > 5R55S > Page 4103
8. NOTICE: 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.
10. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the
transmission vehicle harness connector.
Electrostatic discharge may occur and may cause damage to the mechatronic unit.
With the release tab down, pull the outer shell of the transmission vehicle harness connector out of
the mechatronic assembly.
11. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the
mechatronic unit. Electrostatic discharge may
occur and may cause damage to the mechatronic unit.
Pull the transmission vehicle harness electrical connector out of the transmission.
12. NOTICE: During removal of the mechatronic assembly, the thermal bypass valve will fall out of
the transmission case. Damage to the
valve will occur if the valve falls out.
Remove the 11 bolts from the mechatronic assembly and remove the mechatronic assembly and
the bypass valve.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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System Information > Service and Repair > 5R55S > Page 4104
13. Remove the park rod actuating plate.
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 lever and the park rod as an assembly.
15. Remove and discard the manual control lever seal.
Installation
1. Position a new manual control lever seal in place.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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System Information > Service and Repair > 5R55S > Page 4105
2. Using the Shift Shaft Fluid Seal Installer, install a new manual control lever shaft seal.
3. Install the manual lever in the case.
1. Slide the manual lever in the case.
2. Position the spacer in place while sliding the manual lever into the spacer.
3. Position the manual valve inner lever while sliding the manual lever and lining up the roll pin
hole.
4. Install the roll pin.
4. Position the 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 rod actuating plate.
- Tighten to 12 Nm (106 lb-in).
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 tubes.
2. Green feed tube.
3. Blue feed tube.
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System Information > Service and Repair > 5R55S > Page 4106
7. Verify the rubber adapter is in place.
8. Coat the thermal bypass valve with petroleum jelly to hold it in place and install the thermal
bypass valve in the transmission case.
9. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the
transmission vehicle harness connector.
Electrostatic discharge may occur and may cause damage to the mechatronic unit.
Position the mechatronic assembly in place and loosely install the 11 bolts.
1. Align the manual valve and control lever linkage.
10. Tighten the mechatronic bolts in the sequence shown.
- Tighten to 8 Nm (71 lb-in).
11. NOTICE: Do not touch the electrical connector pins. Electrostatic discharge may occur and will
cause damage to the mechatronic unit.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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System Information > Service and Repair > 5R55S > Page 4107
With the release tab down and unlocked, push the outer shell of the transmission vehicle harness
connector into the transmission. Make sure that the transmission vehicle harness connector is fully
seated into the mechatronic assembly.
12. Press up on the tab and lock the outer shell of the transmission vehicle harness connector in
place.
13. Install a new transmission fluid filter.
14. NOTE: The transmission 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 transmission fluid pan bolts in a crisscross
pattern.
- Tighten to 12 Nm (106 lb-in).
16. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to
lock it in place.
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System Information > Service and Repair > 5R55S > Page 4108
17. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable end
to make sure that the selector lever cable end is correctly installed onto the manual control lever
ball stud.
With the manual lever in NEUTRAL, connect the selector lever cable onto the manual control lever
ball stud and move the locking tab down.
1. Selector lever cable end.
2. Locking tab.
- 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 heat shield.
19. Using the refill procedure, fill and check the transmission fluid. For additional information, refer
to Transmission Fluid Drain and Refill See:
Service and Repair/Procedures/6R80/Transmission Fluid Drain and Refill.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Description and Operation
Brake Switch - TCC: Description and Operation
Engine Control Components
Brake Pedal Position (BPP) Switch
The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal
to the PCM indicating the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Typical BPP Switch
Typical BPP Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Description and Operation
Transmission Mode Switch: Description and Operation
Engine Control Components
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.
Typical Transmission Control Switch (TCS) (Column Shift)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS) (Floor Shift)
Typical Transmission Control Switch (TCS)
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control Switch (TCS)
Transmission Mode Switch: Service and Repair Transmission Control Switch (TCS)
External Controls
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) is a momentary contact switch located on the selector
lever knob. Pushing the TCS will either disengage or engage the overdrive function of the
transmission. If OVERDRIVE is disengaged, the message Overdrive (O/D) OFF will illuminate on
the Instrument Cluster (IC).
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> Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control Switch (TCS) >
Page 4118
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch
Transmission Control (TC) Switch
Removal
1. Remove the selector lever knob. For additional information, refer to Selector Lever Knob See:
Shifter A/T/Service and Repair/Selector Lever
Knob.
2. Remove the Transmission Control Switch (TCS) from the knob.
Installation
1. Install the TCS into the selector lever knob.
2. Install the selector lever knob. For additional information, refer to Selector Lever Knob See:
Shifter A/T/Service and Repair/Selector Lever Knob.
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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
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> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4122
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4123
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4124
Transmission Position Switch/Sensor: Adjustments
5R55S
Transmission Range (TR) Sensor Adjustment
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 Transmission Range (TR) sensor connector.
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable end from the manual control lever.
6. Remove the manual control lever nut and the manual control lever.
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> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4125
7. Loosen but do not remove the TR sensor screws.
8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence.
- Tighten to 8 Nm (71 lb-in).
9. Install the manual control lever and manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
11. Reconnect the TR sensor connector.
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> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4126
12. Reinstall the rubber boot over the TR 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, A/T > Component Information > Locations > Page 4127
Transmission Position Switch/Sensor: Service and Repair
5R55S
Digital Transmission Range (TR) Sensor
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
3. Move the TR sensor connector boot back to gain access to the TR sensor connector.
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> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4128
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable from the manual control lever.
6. Remove the manual control lever nut.
7. Remove the TR sensor.
Installation
1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to
prevent damage to the sensor.
Install the TR sensor and loosely install the TR sensor screw and washer (2 required).
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> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4129
2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual control lever must be in the NEUTRAL position.
Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence. Tighten to 8 Nm (71 lb-in).
3. Install the manual control lever and the manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
5. Connect the TR sensor connector.
6. Move the TR sensor connector boot back over the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4130
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 (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
4135
Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
4136
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
4137
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page
4140
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page
4141
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor >
Page 4144
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the Turbine Shaft Speed (TSS) sensor 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor >
Page 4145
Installation
All vehicles
1. Inspect the TSS O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the TSS sensor connector.
3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever bracket and selector lever bracket screws.
- Tighten to 40 Nm (30 lb-ft).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor >
Page 4146
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor >
Page 4147
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor >
Page 4148
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
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 connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor >
Page 4149
9. Remove the OSS sensor.
1. Remove the OSS sensor screw.
2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
All vehicles
1. Inspect the OSS O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the OSS sensor connector.
3. Connect the HO2S connector to the transmission case.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor >
Page 4150
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever cable bracket and selector lever cable bracket
screws.
- 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.
7. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
8. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor >
Page 4151
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor >
Page 4152
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor >
Page 4153
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the intermediate shaft speed sensor 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor >
Page 4154
Installation
All vehicles
1. Inspect the O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the intermediate shaft speed sensor connector.
3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever cable bracket and selector lever cable bracket
screws.
- Tighten to 40 Nm (30 lb-ft).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor >
Page 4155
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal
1. Remove the front floor console.
2. Disconnect the Brake Shift Interlock Actuator (BSIA) electrical connector.
3. Remove the screw and the BSIA.
Installation
1. Install the BSIA and the screw.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Solenoid > Component Information > Service and Repair > Page 4160
2. Connect the BSIA electrical connector.
3. Install the front floor console.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal
1. Remove the front floor console.
2. Disconnect the selector lever cable from the selector lever.
3. Disconnect the selector lever cable from the selector lever housing.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 4165
4. Disconnect the selector lever housing electrical connector.
5. Disconnect the wiring harness from the selector lever housing.
6. Remove the 4 nuts and remove the selector lever housing from the vehicle.
Installation
1. Install the selector lever housing.
- Tighten to 9 Nm (80 lb-in).
2. Connect the wiring harness to the selector lever housing.
3. Connect the selector lever housing electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 4166
4. Install the selector lever cable onto the selector lever housing.
5. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end
is correctly installed onto the selector housing.
Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly
installed onto the selector lever housing.
Install the selector lever cable end onto the selector lever housing.
6. Install the front floor console.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 4167
Shifter A/T: Service and Repair Selector Lever Knob
Selector Lever Knob
Removal
1. Remove the front floor console.
2. Disconnect the Transmission Control Switch (TCS) electrical connector and feed the wire
through the selector lever housing.
3. Slide the selector lever knob lower trim cover downward.
4. Remove the set screw and remove the selector lever knob while routing the TCS harness out of
the selector lever housing.
Installation
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 4168
1. NOTICE: 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 TCS harness through the selector
lever housing.
- Tighten to 3 Nm (27 lb-in).
2. Slide the selector lever knob lower trim cover upward.
3. Feed the wire through the selector lever housing and connect the TCS electrical connector.
4. Install the front floor console.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 4169
Shifter A/T: Service and Repair Selector Lever Bezel
Selector Lever Bezel
Removal
1. Remove the front floor console.
2. Disconnect the Transmission Control Switch (TCS) electrical connector and feed the wire
through the selector lever housing.
3. Slide the selector lever knob lower trim cover downward.
4. Remove the set screw and remove the selector lever knob while routing the TCS harness out of
the selector lever housing.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 4170
5. Remove the selector lever bezel from the selector lever housing.
Installation
1. Install the selector lever bezel onto the selector lever housing.
2. NOTICE: 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 TCS harness through the selector
lever housing.
- Tighten to 3 Nm (27 lb-in).
3. Slide the selector lever lower trim cover upward.
4. Feed the wire through the selector lever housing and connect the TCS electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 4171
5. Install the front floor console.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Service and Repair
Shift Cable: Service and Repair
Selector Lever Cable
Vehicles Equipped With a 6R80 Transmission
Vehicles Equipped With a 5R55S Transmission
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the front floor console left side panel.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Service and Repair > Page 4176
3. With the selector lever in PARK, disconnect the selector lever cable from the selector lever.
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 6R80 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.
7. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Unlock the lock tab and disconnect the selector lever cable end from the manual control lever.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Service and Repair > Page 4177
1. Lock tab.
2. Selector lever cable end.
3. 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.
10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Service and Repair > Page 4178
Vehicles equipped with a 6R80 transmission
1. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable end
to make sure that the selector lever cable end is correctly installed onto the manual control lever
ball stud.
Install the selector lever cable into the selector lever cable bracket.
2. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable end
to make sure that the selector lever cable end is correctly installed onto the manual control lever
ball stud.
Install the selector lever cable end onto the manual control lever ball stud and lock the tab.
1. Selector lever cable end.
2. Lock tab.
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. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Service and Repair > Page 4179
ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud.
Install the selector lever cable into the selector lever cable bracket.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable end
to make sure that the selector lever cable end is correctly installed onto the manual control lever
ball stud.
Install the selector lever cable end onto the manual control lever ball stud and lock the tab.
1. Selector lever cable end.
2. Lock tab.
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Service and Repair > Page 4180
9. Connect the selector lever cable onto the selector lever.
10. Install the front floor 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. For
additional information, refer to Selector Lever Cable Adjustment - 5R55S See:
Adjustments/External Controls/Selector Lever Cable Adjustment - 5R55S or Selector Lever Cable
Adjustment - 6R80 See: Adjustments/External Controls/Selector Lever Cable Adjustment - 6R80.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Description and Operation
Torque Converter: Description and Operation
6R80
Torque Converter
The torque converter is a 4-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 4 elements:
- Impeller assembly
- Turbine assembly
- Reactor assembly
- Torque Converter Clutch (TCC)
Rotation of the torque converter housing and impeller set the transmission fluid in motion by driving
the impeller blades and pump.
The turbine is driven by the transmission fluid from the impeller and transmits power to the input
shaft.
The reactor redirects transmission fluid flow returned from the turbine to the impeller so that it
rotates in the same direction as the impeller. This action assists in torque multiplication.
The reactor has a One-Way Clutch (OWC) to hold it stationary during torque multiplication and
allows it to rotate at higher vehicle speeds.
Torque Converter Operation
Torque Converter Clutch (TCC)
The TCC has a cover assembly with a 3-plate clutch and a turbine and damper assembly that
connects to the transmission input shaft.
The TCC connects the cover to the turbine when the TCC is applied.
During TCC release, transmission fluid flows through the torque converter in one direction to
release the 3-plate clutch.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Description and Operation > Page 4184
During TCC apply, transmission fluid flows through the torque converter in the opposite direction to
apply the 3-plate clutch.
The TCC operates in 3 stages:
- Full release
- Controlled modulation
- Full apply
The Transmission Control Module (TCM) controls TCC operation using the TCC solenoid. TCC
solenoid operation provides the modulation of hydraulic pressure to change the position of the
bypass clutch control regulator valve. The valve changes the pressure and direction of
transmission fluid flow in the torque converter. The TCC may be applied in forward gears, 2 to 6.
Torque Converter Exploded View
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > 5R55S
Torque Converter: Testing and Inspection 5R55S
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. For additional information, refer to Torque
Converter Contamination Inspection See: Testing and Inspection/Component Tests and General
Diagnostics/5R55S/Torque Converter Contamination Inspection.
Torque Converter Diagnosis
Torque Converter Diagnosis
Prior to installing a new torque converter, all diagnostic procedures must be followed. This is to
prevent the unnecessary installation of a good torque converter. 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 (TCC) Operation Test. Refer to
Torque Converter Operation Test.
4. Carry out diagnostic procedures.
- Run On-Board Diagnostic (OBD). See On-Board Diagnostics with Scan Tool. Refer to Diagnostics
See: Transmission Control Systems/Testing and Inspection/Initial Inspection and Diagnostic
Overview/5R55S/Diagnostics. Repair all non-transmission related DTCs first.
- Repair all transmission DTCs.
- Rerun OBD test 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/Special
Testing Procedures.
- Carry out the Stall Speed Test. Refer to Special Testing Procedures. See: Transmission Control
Systems/Testing and Inspection/Component Tests and General Diagnostics/5R55S/Special
Testing Procedures/Stall Speed Test See: Transmission Control Systems/Testing and
Inspection/Component Tests and General Diagnostics/5R55S/Special Testing Procedures
- Carry out the Diagnosis by Symptom Index. Refer to Diagnosis By Symptom See: Transmission
Control Systems/Testing and Inspection/Symptom Related Diagnostic
Procedures/5R55S/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
This test verifies that the TCC control system and the torque converter are operating correctly.
1. Carry out the Self Test. See On-Board Diagnostics with Scan Tool. Refer to Diagnostics See:
Transmission Control Systems/Testing and
Inspection/Initial Inspection and Diagnostic Overview/5R55S/Diagnostics. Check for DTCs. Refer to
the Diagnostic Trouble Code (DTC) Charts
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > 5R55S > Page 4187
See: Transmission Control Systems/Testing and Inspection/Diagnostic Trouble Code
Descriptions/5R55S.
2. Connect a scan tool to the vehicle and monitor engine rpm.
3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds in the
(D) position.
4. After normal operating temperature is reached, maintain a constant vehicle speed of about 80
km/h (50 mph) and tap the 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/5R55S/Diagnosis By Symptom.
6. If the vehicle stalls in (D) or MANUAL 2 at idle with the vehicle stopped, move the selector lever
to MANUAL 1 position. If the vehicle stalls,
refer to Diagnosis By Symptom See: Transmission Control Systems/Testing and
Inspection/Symptom Related Diagnostic Procedures/5R55S/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/5R55S/Diagnosis By Symptom.
Torque Converter Contamination Inspection
Torque Converter Contamination Inspection
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.
- The torque converter stud or studs, impeller hub or bushing are damaged.
- The torque converter exhibits external discoloration (due to overheating).
- There is evidence of transmission assembly or fluid contamination due to the following
transmission or converter failure modes. Major metallic failure
- Multiple clutch plates or band failures
- Sufficient component wear which results in metallic contamination
- Water or antifreeze contamination
2. If none of the above conditions are present, continue with the following fluid inspection.
3. Pour a small amount of transmission fluid from the torque converter onto an absorbent white
tissue or through a paper filter.
4. Examine the fluid for contaminants, color and smell. The fluid must be free of contaminants, red
in color and not have a burnt smell.
5. NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque
converter or transmission damage will occur.
If the fluid passed inspection:
- drain the remaining fluid from the torque converter.
- using only the recommended transmission fluid, add 1.9L (2 qt) of clean fluid into the converter
and agitate by hand.
- thoroughly drain the fluid.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > 5R55S > Page 4188
Torque Converter: Testing and Inspection 6R80
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 concern.
3. Verify the condition - carry out the Torque Converter Operation Test.
4. Perform diagnostic procedures.
- Perform On-Board Diagnostic (OBD) test. Refer to Diagnostics See: Transmission Control
Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/6R80/Diagnostics. Repair all non-transmission related DTCs first.
- Repair all transmission-related DTCs.
- Rerun OBD test to verify repair.
- Perform Stall Speed Test. Refer to Special Testing Procedures See: Transmission Control
Systems/Testing and Inspection/Component Tests and General Diagnostics/6R80/Special Testing
Procedures.
- Perform Diagnostic Routines. Refer to Diagnosis By Symptom. See: Transmission Control
Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/6R80/Diagnostic
Routines See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic
Procedures/6R80/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. Perform a Self Test with the scan tool. Refer to Computers and Control Systems Information.
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 in the
(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 Throttle Position (TP) voltage to
approximately 1.25 volts or 25% throttle.
6. Monitor the TCC and RPM TCM 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 the appropriate systems of the
diagnostic/repair information and Computers and Control Systems Information.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > 5R55S > Page 4189
- Spark plugs - check for cracks, high resistance or broken insulators
- Spark 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) and 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
Torque Converter Contamination Inspection
Torque Converter Contamination Inspection
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.
- The torque converter stud or studs, impeller hub or bushing are damaged.
- The torque converter exhibits external discoloration (due to overheating).
- There is evidence of transmission assembly or fluid contamination due to the following
transmission or converter failure modes. Major metallic failure
- Multiple clutch plates or band failures
- Sufficient component wear which results in metallic contamination
- Water or antifreeze contamination
2. If none of the above conditions are present, continue with the following fluid inspection.
3. Pour a small amount of transmission fluid from the torque converter onto an absorbent white
tissue or through a paper filter.
4. Examine the fluid for contaminants, color and smell. The fluid must be free of contaminants, red
in color and not have a burnt smell.
5. NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque
converter or transmission damage will occur.
If the fluid passed inspection:
- drain the remaining fluid from the torque converter.
- using only the recommended transmission fluid, add 1.9L (2 qt) of clean fluid into the converter
and agitate by hand.
- thoroughly drain the fluid.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > General Specifications
Transmission Cooler: Specifications General Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > General Specifications > Page 4194
Transmission Cooler: Specifications Material
a 5R55S Transmission
b 6R80 Transmission
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > General Specifications > Page 4195
Transmission Cooler: Specifications Torque Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > Page 4196
Transmission Cooler: Description and Operation
Transmission Cooling
Vehicles equipped with automatic transmissions have an auxiliary transmission fluid cooler which is
mounted in front of the radiator and the A/C condenser. In operation, transmission fluid travels from
the transmission to the auxiliary transmission fluid cooler then back to the transmission. The
auxiliary transmission fluid cooler transfers heat from the transmission fluid to the outside air.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Inspection and Verification
NOTICE: Whenever a transmission has been disassembled to install new parts, the transmission
fluid cooler and/or auxiliary cooler should be replaced and the transmission fluid cooler tubes must
be cleaned and backflushed to keep contaminants from entering the transmission, causing internal
damage.
NOTE: Cleaning and backflushing the transmission fluid cooler tubes, 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 failure and must be
removed from the transmission cooler system before the transmission is put back into use. Install a
new transmission fluid cooler and/or auxiliary cooler and backflush the transmission fluid cooler
tubes.
When transmission fluid leakage is found in the transmission fluid cooler, install a new transmission
fluid cooler.
If the fault is not visually evident, GO to Symptom Chart - Transmission Cooling or GO to Symptom
Chart - NVH. See: Symptom Related Diagnostic Procedures/Symptom Chart - Transmission
Cooling See: Symptom Related Diagnostic Procedures/Symptom Chart - NVH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4199
Transmission Cooler: Symptom Related Diagnostic Procedures
Symptom Chart - Transmission Cooling
Transmission Cooling
Symptom Chart - Transmission Cooling
Symptom Chart - Transmission Cooling
Symptom Chart - NVH
Transmission Cooling
Symptom Chart - NVH
Symptom Chart - NVH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4200
Transmission Cooler: Component Tests and General Diagnostics
Transmission Fluid Cooler
6R80
Transmission Fluid Cooler
NOTICE: Whenever a transmission has been disassembled to install new parts, the transmission
fluid cooler and/or auxiliary cooler should be replaced and the transmission fluid cooler tubes must
be cleaned and backflushed to keep contaminants from entering the transmission, causing internal
damage.
NOTE: Cleaning and backflushing the transmission fluid cooling tubes, 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 failure and must be
removed from the transmission cooling system before the transmission is put back into use. Install
a new transmission fluid cooler and/or auxiliary cooler and backflush the transmission fluid cooler
tubes.
Transmission Fluid Cooler Backflushing and Cleaning
6R80
Transmission Fluid Cooler Backflushing and Cleaning
NOTICE: Use only transmission fluid specified for this transmission. Do not use any supplemental
transmission fluid additives or cleaning agents. The use of these products could cause internal
transmission components to fail; this will affect the operation of the transmission.
NOTE: Transmission fluid cooler backflushing and cleaning will be performed using the Turbo-Tank
Heated Cooler Line Flusher or equivalent. Follow the manufacturer's instructions included with the
machine. Test the equipment to make sure that a vigorous fluid flow is present before proceeding.
NOTE: If the vehicle is equipped with an in-line transmission fluid filter, remove and discard the
in-line filter.
1. Check and top off fluid level of the Turbo-Tank Heated Cooler Line Flusher or equivalent tank
with transmission fluid.
2. Allow the fluid in the Turbo-Tank Heated Cooler Line Flusher or equivalent 15-30 minutes to heat
up to 60°C (140°F) before using.
3. Install the line adapters into the transmission cooler lines.
4. Attach the Turbo-Tank Heated Cooler Line Flusher or equivalent red line to the transmission fluid
cooler pressure line quick disconnect fitting.
5. Attach the Turbo-Tank Heated Cooler Line Flusher or equivalent blue line to the transmission
fluid cooler return line quick disconnect fitting.
6. Follow the equipment instructions to purge the cooler lines and cooler prior to starting the
flushing procedure.
7. Allow the cooling system to backflush for 10-15 minutes, then flush the cooler in a normal flow
direction for an additional 10-15 minutes.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures
Transmission Cooler: Procedures
5R55S
Transmission Fluid Cooler Backflushing and Cleaning
NOTICE: 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.
NOTICE: 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 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 tubes, connect 2 additional rubber
hoses to the transmission end of the steel
transmission cooler tubes as described. 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 tubes (blow air into the transmission cooler
return tube) 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 Transmission Control Systems. See: Transmission Control Systems/Testing and
Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4203
Transmission Cooler: Removal and Replacement
Auxiliary Transmission Fluid Cooler
Auxiliary Transmission Fluid Cooler
Removal
NOTE: 5R55S uses MERCON(R) V Automatic Transmission Fluid. 6R80 uses Motorcraft
MERCON(R) LV Automatic Transmission Fluid.
Mountaineer
1. Remove the grille fasteners and the grille.
Explorer
2. Remove the front bumper cover.
All vehicles
3. Remove the 5 bolts and remove the inner grille air deflector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4204
4. Push the lower air deflector down past the transmission fluid cooler.
5. Disconnect the transmission fluid cooler hoses.
- Remove and discard the transmission fluid cooler hoses and the clamps.
6. Remove the upper transmission fluid cooler bolt.
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-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4205
2. Install the upper transmission fluid cooler bolt.
- Tighten to 7 Nm (62 lb-in).
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.
5. Install the inner grille air deflector.
Mountaineer
6. Install the grille and the fasteners.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4206
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.
Transmission Fluid Cooler Tubes - 5R55S
Transmission Fluid Cooler Tubes - 5R55S
Removal
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4207
3. Remove the secondary latch from the cooler tube.
4. Using the Transmission Cooler Line Disconnect 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.
6. Using the Transmission Cooler Line Disconnect 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4208
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).
4. NOTICE: 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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4209
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.
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 leaks.
Transmission Fluid Cooler Tubes - 6R80
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4210
Transmission Fluid Cooler Tubes - 6R80
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4211
3. Using the Transmission Cooler Line Disconnect 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 Transmission Cooler Line Disconnect 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4212
9. Disconnect the engine oil low level sensor electrical connector and harness clips.
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4213
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 (106 lb-in).
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 and sealer.
If removed, install the U-joint straps and 4 new U-joint strap bolts.
- Tighten to 19 Nm (168 lb-in).
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4214
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.
Transmission Fluid Cooler Hoses
Transmission Fluid Cooler Hoses
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4215
Removal
NOTE: 5R55S uses MERCON(R) V Automatic Transmission Fluid. 6R80 uses Motorcraft
MERCON(R) LV Automatic Transmission Fluid.
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4216
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 Transmission Cooler Line Disconnect Tool, disconnect the quick connect coupler and
separate the transmission fluid cooler tube from
the transmission cooler hose.
9. Remove the secondary latch from the transmission fluid cooler hose.
10. Using the Transmission Cooler Line Disconnect Tool, disconnect the quick connect coupler and
remove the transmission fluid cooler hose from
the radiator.
11. Remove the hoses from the retainer.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4217
Installation
All vehicles
1. Install the hoses into the retainer.
2. Install the transmission fluid cooler hose to the radiator.
3. Install the secondary latch.
4. Install the transmission fluid cooler hose to the transmission fluid cooler tube.
5. Install the secondary latch.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4218
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.
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 (V6-4.0L (2009))
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
Engine Control Components
Transmission Control Indicator Lamp (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Description and Operation
Transmission Mode Switch: Description and Operation
Engine Control Components
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.
Typical Transmission Control Switch (TCS) (Column Shift)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS) (Floor Shift)
Typical Transmission Control Switch (TCS)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Service and Repair > Transmission Control Switch (TCS)
Transmission Mode Switch: Service and Repair Transmission Control Switch (TCS)
External Controls
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) is a momentary contact switch located on the selector
lever knob. Pushing the TCS will either disengage or engage the overdrive function of the
transmission. If OVERDRIVE is disengaged, the message Overdrive (O/D) OFF will illuminate on
the Instrument Cluster (IC).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Service and Repair > Transmission Control Switch (TCS) > Page 4227
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch
Transmission Control (TC) Switch
Removal
1. Remove the selector lever knob. For additional information, refer to Selector Lever Knob See:
Shifter A/T/Service and Repair/Selector Lever
Knob.
2. Remove the Transmission Control Switch (TCS) from the knob.
Installation
1. Install the TCS into the selector lever knob.
2. Install the selector lever knob. For additional information, refer to Selector Lever Knob See:
Shifter A/T/Service and Repair/Selector Lever Knob.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Service and Repair
Transmission Mount: Service and Repair
5R55S
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-to-crossmember nuts.
4. Remove the 2 transmission support insulator-to-extension housing screws.
5. Raise the transmission and remove the transmission support insulator.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Service and Repair > Page 4231
Installation
1. Install the transmission support insulator and lower the transmission onto the transmission
support insulator.
2. Install the 2 transmission support insulator-to-extension housing screws.
- Tighten to 90 Nm (66 lb-ft).
3. Install the 2 transmission support insulator-to-crossmember nuts.
- Tighten to 90 Nm (66 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations
Transmission Position Switch/Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4235
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4236
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4237
Transmission Position Switch/Sensor: Adjustments
5R55S
Transmission Range (TR) Sensor Adjustment
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 Transmission Range (TR) sensor connector.
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable end from the manual control lever.
6. Remove the manual control lever nut and the manual control lever.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4238
7. Loosen but do not remove the TR sensor screws.
8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence.
- Tighten to 8 Nm (71 lb-in).
9. Install the manual control lever and manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
11. Reconnect the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4239
12. Reinstall the rubber boot over the TR 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4240
Transmission Position Switch/Sensor: Service and Repair
5R55S
Digital Transmission Range (TR) Sensor
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
3. Move the TR sensor connector boot back to gain access to the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4241
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable from the manual control lever.
6. Remove the manual control lever nut.
7. Remove the TR sensor.
Installation
1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to
prevent damage to the sensor.
Install the TR sensor and loosely install the TR sensor screw and washer (2 required).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4242
2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual control lever must be in the NEUTRAL position.
Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence. Tighten to 8 Nm (71 lb-in).
3. Install the manual control lever and the manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
5. Connect the TR sensor connector.
6. Move the TR sensor connector boot back over the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4243
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4248
Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4249
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4250
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page 4253
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page 4254
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4257
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the Turbine Shaft Speed (TSS) sensor 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4258
Installation
All vehicles
1. Inspect the TSS O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the TSS sensor connector.
3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever bracket and selector lever bracket screws.
- Tighten to 40 Nm (30 lb-ft).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4259
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4260
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4261
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
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 connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4262
9. Remove the OSS sensor.
1. Remove the OSS sensor screw.
2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
All vehicles
1. Inspect the OSS O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the OSS sensor connector.
3. Connect the HO2S connector to the transmission case.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4263
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever cable bracket and selector lever cable bracket
screws.
- 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.
7. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
8. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4264
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4265
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4266
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the intermediate shaft speed sensor 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4267
Installation
All vehicles
1. Inspect the O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the intermediate shaft speed sensor connector.
3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever cable bracket and selector lever cable bracket
screws.
- Tighten to 40 Nm (30 lb-ft).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4268
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 09-21-4 > Nov > 09 > A/T - Whistling Noise
When Hot
Valve Body: Customer Interest A/T - Whistling Noise When Hot
TSB 09-21-4
11/02/09
5R555 TRANSMISSION - WHISTLE NOISE WHEN HOT
FORD: 2009-2010 Explorer Sport Trac, Explorer
MERCURY: 2009-2010 Mountaineer
This article supersedes TSB 09-12-5 to update the Service Procedure and Part List.
ISSUE Some 2009-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a
5R55S transmission may exhibit a high frequency whistle noise at idle in any gear position with the
transmission fluid temperature at or above 170 degrees Fahrenheit (76 degrees Celsius).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install IDS/PDS or equivalent.
2. Verify that the transmission fluid temperature (TFT) PID is above 170 °F (76 °C).
a. If it is not at 170 °F (76 °C), drive unit approximately 3 miles (5 Km) to reach temperature.
b. If it is at 170 °F (76 °C), proceed to Step 3.
3. Return vehicle to idle and verify high frequency whistle noise is present in all gear selector
positions (P-R-N-D-L). While Vehicle is at idle in park
increase engine RPM by 150 to 200 RPM's the whistle noise will go away.
a. If the above whistle condition can be verified in all gears proceed Step 4.
b. If the whistle condition cannot be verified or is not present in all selector gear positions please
follow the normal diagnostic routine procedures
outlined in the Workshop Manual (WSM), Section 307-01.
4. Replace the main control separator plate following the WSM, Section 307-01A for Main Control
Removal and Disassembly and Assembly of
Subassemblies Main Control Valve Body.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 09-21-4 > Nov > 09 > A/T - Whistling Noise
When Hot > Page 4277
NOTE
VERIFY THE NEW REPLACEMENT SEPARATOR PLATE HAS TWO (2) ORIFICE LOCATIONS
TO ASSURE YOU HAVE THE LATEST LEVEL. (FIGURES 1-2)
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
092104A 2009-2010 Explorer, 2.2 Hrs.
Mountaineer, Explorer Sport Trac: Replace The Main Control Separator Plate And Includes Time
To Diagnose (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7Z490 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-4 > Nov > 09 > A/T Whistling Noise When Hot
Valve Body: All Technical Service Bulletins A/T - Whistling Noise When Hot
TSB 09-21-4
11/02/09
5R555 TRANSMISSION - WHISTLE NOISE WHEN HOT
FORD: 2009-2010 Explorer Sport Trac, Explorer
MERCURY: 2009-2010 Mountaineer
This article supersedes TSB 09-12-5 to update the Service Procedure and Part List.
ISSUE Some 2009-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a
5R55S transmission may exhibit a high frequency whistle noise at idle in any gear position with the
transmission fluid temperature at or above 170 degrees Fahrenheit (76 degrees Celsius).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install IDS/PDS or equivalent.
2. Verify that the transmission fluid temperature (TFT) PID is above 170 °F (76 °C).
a. If it is not at 170 °F (76 °C), drive unit approximately 3 miles (5 Km) to reach temperature.
b. If it is at 170 °F (76 °C), proceed to Step 3.
3. Return vehicle to idle and verify high frequency whistle noise is present in all gear selector
positions (P-R-N-D-L). While Vehicle is at idle in park
increase engine RPM by 150 to 200 RPM's the whistle noise will go away.
a. If the above whistle condition can be verified in all gears proceed Step 4.
b. If the whistle condition cannot be verified or is not present in all selector gear positions please
follow the normal diagnostic routine procedures
outlined in the Workshop Manual (WSM), Section 307-01.
4. Replace the main control separator plate following the WSM, Section 307-01A for Main Control
Removal and Disassembly and Assembly of
Subassemblies Main Control Valve Body.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-4 > Nov > 09 > A/T Whistling Noise When Hot > Page 4283
NOTE
VERIFY THE NEW REPLACEMENT SEPARATOR PLATE HAS TWO (2) ORIFICE LOCATIONS
TO ASSURE YOU HAVE THE LATEST LEVEL. (FIGURES 1-2)
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
092104A 2009-2010 Explorer, 2.2 Hrs.
Mountaineer, Explorer Sport Trac: Replace The Main Control Separator Plate And Includes Time
To Diagnose (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7Z490 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-14-3 > Jul > 09 >
SYNC(R) System - Functions Inoperative/DTC's Set > Page 4289
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-14-3 > Jul > 09 >
SYNC(R) System - Functions Inoperative/DTC's Set > Page 4290
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4295
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4296
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4297
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4298
^ 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4299
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4300
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4301
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4302
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4303
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4304
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4305
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-11-8 > Jun > 09 >
SYNC(R) System - 911 Assist VHR Software Upgrade > Page 4310
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-11-8 > Jun > 09 >
SYNC(R) System - 911 Assist VHR Software Upgrade > Page 4311
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-14-3 > Jul > 09 >
SYNC(R) System - Functions Inoperative/DTC's Set > Page 4317
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-14-3 > Jul > 09 >
SYNC(R) System - Functions Inoperative/DTC's Set > Page 4318
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4323
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4324
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4325
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4326
^ 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4327
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4328
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4329
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4330
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4331
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4332
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 4333
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-11-8 > Jun > 09 >
SYNC(R) System - 911 Assist VHR Software Upgrade > Page 4338
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-11-8 > Jun > 09 >
SYNC(R) System - 911 Assist VHR Software Upgrade > Page 4339
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 4340
Valve Body: Locations
6R80 Transmission
Mechatronic Assembly
Item 3 - Check Ball Location
Items 1-8 - Check Ball Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 4341
NOTE: Note where the 8 check balls are located for reassembly.
Item 2 - Check Ball Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 4342
Valve Body: Diagrams
6R80 Transmission
Mechatronic Assembly
Mechatronic
Mechatronic Upper Half
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 4343
Mechatronic Lower Half
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 4344
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 4345
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 4346
Check Ball Location
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S
Valve Body: Service and Repair 5R55S
Main Control Valve Body
Main Control Valve Body
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S > Page 4349
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If equipped, remove the transmission fluid pan drain plug and drain the transmission fluid.
3. NOTE: Clean the area around the transmission vehicle harness connector to prevent
contamination of the transmission control solenoid vehicle
harness connector.
Disconnect the transmission vehicle 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S > Page 4350
5. Remove the transmission fluid 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.
9. Remove the main control valve body screws and the main control valve body.
Installation
1. Install the Valve Body Aligners into the transmission case.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S > Page 4351
2. Using the Valve Body Aligners, install the main control valve body and loosely install the main
control valve body-to-case screws.
1. Install the short main control valve body-to-case screw.
2. Install the main control valve body-to-case screw with the larger head.
3. Install the remaining main control valve body-to-case screws.
3. Remove the Valve Body Aligners 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-in).
5. Install the manual control valve detent spring screw.
- Tighten to 10 Nm (89 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S > Page 4352
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-in).
- Stage 2: Tighten to 11 Nm (97 lb-in).
7. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with transmission fluid.
8. NOTICE: 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-in).
9. NOTICE: Damage may occur to transmission fluid filter seals if they are not lubricated with
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 filter. Tighten the
transmission fluid filter screws.
- Tighten to 10 Nm (89 lb-in).
10. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S > Page 4353
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-to-case screws.
12. Tighten the transmission fluid pan-to-case screws in a crisscross sequence.
- Tighten to 11 Nm (97 lb-in).
13. NOTICE: Damage will occur to the transmission vehicle harness connector if the screw is
tightened above specification.
NOTE: Always install new O-ring seals on the transmission control solenoid body connector.
NOTE: Clean the area around the transmission vehicle harness connector to prevent
contamination of the transmission control solenoid body connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission control solenoid body harness connector
and connect the connector. Tighten to 5 Nm (44 lb-in).
14. Fill the transmission. For additional information, refer to Transmission Fluid Exchange See:
Service and Repair/Procedures/5R55S/Transmission
Fluid Exchange or Transmission Fluid Drain and Refill See: Service and
Repair/Procedures/5R55S/Transmission Fluid Drain and Refill.
Solenoid Body Assembly
Solenoid Body Assembly
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S > Page 4354
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the transmission fluid pan drain plug and drain the transmission fluid.
3. NOTE: Clean the area around the transmission vehicle harness connector to prevent
contamination of the transmission control solenoid vehicle
harness connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S > Page 4355
Disconnect the transmission vehicle 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-to-case screws, transmission fluid pan and transmission fluid
pan gasket.
5. Remove the transmission fluid filter.
6. NOTICE: 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 transmission fluid.
2. NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S > Page 4356
- Tighten to 8 Nm (71 lb-in).
3. NOTICE: Damage may occur to transmission fluid filter seals if they are not lubricated with
transmission fluid.
NOTE: Make sure that the transmission fluid filter seals are correctly seated on the transmission
fluid filter.
Lubricate the transmission fluid seals and install the transmission fluid filter.
- Tighten to 10 Nm (89 lb-in).
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-to-case screws.
5. Tighten the transmission fluid pan-to-case screws in a crisscross sequence.
- Tighten to 11 Nm (97 lb-in).
6. NOTICE: Damage will occur to the transmission vehicle harness connector if the screw is
tightened above specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around the transmission vehicle harness connector to prevent
contamination of the transmission control solenoid body connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission control solenoid body harness connector
and connect the connector. Tighten to 5 Nm (44 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S > Page 4357
7. Fill the transmission. For additional information, refer to Transmission Fluid Exchange See:
Service and Repair/Procedures/5R55S/Transmission
Fluid Exchange or Transmission Fluid Level Check See: Service and
Repair/Procedures/5R55S/Transmission Fluid Level Check.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S > Page 4358
Valve Body: Service and Repair 6R80
Mechatronic Assembly
Removal
Mechatronic assembly
NOTICE: The only solenoid that is serviceable in the mechatronic assembly is Shift Solenoid E
(SSE). If the mechatronic assembly is being removed due to a faulty SSE, follow the specific steps
in this procedure to install a new SSE. If the mechatronic assembly is being removed due to a
faulty solenoid other than SSE, a new mechatronic assembly must be installed.
NOTE: If a new or existing mechatronic assembly is installed, the Transmission Control Module
(TCM) will need to be flashed with the latest calibration level.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. NOTICE: 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 aid in allowing 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S > Page 4359
6. Remove and discard the transmission fluid filter.
7. Pull the release tab and pull down on the bulkhead connector retainer.
8. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the
transmission vehicle harness connector.
Electrostatic discharge may occur and may cause damage to the mechatronic unit.
With the release tab down, pull the outer shell of the transmission vehicle harness connector out of
the mechatronic assembly.
9. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the
transmission vehicle harness connector.
Electrostatic discharge may occur and may cause damage to the mechatronic unit.
Pull the transmission vehicle harness connector out of the transmission.
10. NOTICE: During removal of the mechatronic assembly, the thermal bypass valve will fall out of
the transmission case. Damage to the
valve will occur if the valve falls out.
Remove the 11 bolts from the mechatronic assembly and remove the mechatronic assembly and
the bypass valve.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S > Page 4360
Shift Solenoid E (SSE)
11. Remove the 6 long bolts from the TCM unit.
12. Carefully separate the TCM from the mechatronic assembly.
1. TCM
2. Mechatronic assembly
13. Remove the 8 solenoid bracket bolts and the solenoid bracket.
14. Remove Shift Solenoid E (SSE).
Installation
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S > Page 4361
SSE
1. Install SSE.
2. Position the solenoid bracket in place and install the 8 bolts.
- Tighten to 6 Nm (53 lb-in).
3. Position the TCM on the mechatronic assembly.
1. TCM
2. Mechatronic assembly
4. Install the 6 long bolts into the TCM unit. Tighten the bolts in the sequence shown.
- Tighten to 6 Nm (53 lb-in).
Mechatronic assembly
5. 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 tubes
2. Green feed tube
3. Blue feed tube
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S > Page 4362
6. Verify the rubber adapter is in place.
7. Coat the thermal bypass valve with petroleum jelly to hold it in place and install the thermal
bypass valve in the transmission case.
8. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the
transmission vehicle harness connector.
Electrostatic discharge may occur and may cause damage to the mechatronic unit.
Position the mechatronic assembly in place and loosely install the 11 bolts.
1. Align the manual valve and control lever linkage.
9. Tighten the mechatronic bolts in the sequence shown.
- Tighten to 8 Nm (71 lb-in).
10. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the
transmission vehicle harness connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S > Page 4363
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 transmission vehicle harness
connector into the transmission. Make sure that the transmission vehicle harness connector is fully
seated into the mechatronic assembly.
11. Press up on the tab and lock the outer shell of the transmission vehicle harness electrical
connector in place. Make sure that the locking tab is
securely locked.
12. Install a new transmission fluid filter.
13. NOTE: The transmission fluid pan gasket can be reused if not damaged.
Install a new transmission fluid pan gasket, if required.
14. Install the transmission fluid pan and tighten the transmission fluid pan bolts in a crisscross
pattern.
- Tighten to 12 Nm (106 lb-in).
15. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to
lock it in place.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 5R55S > Page 4364
16. Make sure the transmission fluid is at the correct level, follow the steps for Adding Additional
Transmission Fluid or Removing Transmission
Fluid. For additional information, refer to Transmission Fluid Drain and Refill See: Service and
Repair/Procedures/6R80/Transmission Fluid Drain and Refill.
17. If a new or existing mechatronic assembly is installed, the TCM will need to be flashed with the
latest calibration.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 11-3-25 > Mar > 11 > A/T Fluid Leaks From Bulkhead Connector
Wiring Harness: Customer Interest A/T - Fluid Leaks From Bulkhead Connector
TSB 11-3-25
03/31/11
6R80 TRANSMISSION BULKHEAD CONNECTOR SLEEVE LEAKING TRANSMISSION FLUID
FORD: 2009-2010 Expedition, Explorer Sport Trac, Explorer, F-150
LINCOLN: 2009-2010 Navigator
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 F-150, Expedition, Explorer Sport Trac, Explorer, Mountaineer and
Navigator vehicles equipped with a 6R80 transmission may show signs of transmission fluid
leakage around the transmission bulkhead connector sleeve.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Verify the leak is present at the transmission bulkhead connector sleeve. With the vehicle in
neutral, position it on a hoist. For additional information, refer to Workshop Manual (WSM), Section
100-02.
1. Disconnect the transmission vehicle harness connector by twisting the outer shell and pulling
back on the connector.
2. Remove the transmission fluid pan and allow the transmission fluid to drain.
3. Pull the release tab and pull down on the transmission bulkhead electrical connector retainer.
4. With the release tab down, pull the connector sleeve out of the case/mechatronic assembly.
5. Lube new connector sleeve 0-rings with clean transmission fluid, then install connector sleeve
into case/mechantronic assembly.
6. Press up on the tab and lock the outer shell of the transmission bulkhead electrical connector
sleeve in place. Make sure that the locking tab is
securely locked.
7. Install the transmission fluid pan/gasket and refill transmission fluid refer to WSM, Section
307-01 for refill procedure.
NOTE
DO NOT TOUCH THE ELECTRICAL CONNECTOR PINS OR THE EXPOSED SOLENOID TABS
ON THE TRANSMISSION BULKHEAD ELECTRICAL CONNECTOR. ELECTROSTATIC
DISCHARGE MAY OCCUR AND MAY CAUSE DAMAGE TO THE TRANSMISSION CONTROL
MODULE (TCM).
NOTE
BULKHEAD CONNECTOR SLEEVES MAY COME WITH RED OR BLACK 0-RING SEALS. USE
ONLY BULKHEAD CONNECTOR SLEEVE THAT HAS BLACK 0-RING SEAL FOR THIS
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 11-3-25 > Mar > 11 > A/T Fluid Leaks From Bulkhead Connector > Page 4373
OPERATION DESCRIPTION TIME
110325A 2009-2010 Explorer, 1.7 Hrs.
Mountaineer, Explorer Sport Trac, And F-150: Replace Connector Sleeve Includes Time To
Remove And Install Transmission Fluid Pan (Do Not Use With Any Other Labor Operations)
110325A 2009-2010 Expedition And 1.8 Hrs.
Navigator: Replace Connector Sleeve Includes Time To Remove And Install Transmission Fluid
Pan (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7G276 D8
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 09-22-15 > Nov > 09 > A/T
Controls - MIL ON/Various A/T Solenoid DTC's
Wiring Harness: Customer Interest A/T Controls - MIL ON/Various A/T Solenoid DTC's
TSB 09-22-15
11/16/09
5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION
FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR
BEFORE 8/12/2009
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or
before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with
diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related
DTCs. This may be due to water traveling down from the A/C drain into the solenoid body
connector on the left side of the transmission.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify any transmission related symptoms or transmission related DTC's that are present.
2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be
coming from the A/C drain. (Figure 1)
3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed.
4. Cut and install patch kit over the connector. (Figure 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4378
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092215A 2006-2010 Explorer, 0.4 Hr.
Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease
Connector, Install Patch (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7G391 X2
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 11-3-25 > Mar
> 11 > A/T - Fluid Leaks From Bulkhead Connector
Wiring Harness: All Technical Service Bulletins A/T - Fluid Leaks From Bulkhead Connector
TSB 11-3-25
03/31/11
6R80 TRANSMISSION BULKHEAD CONNECTOR SLEEVE LEAKING TRANSMISSION FLUID
FORD: 2009-2010 Expedition, Explorer Sport Trac, Explorer, F-150
LINCOLN: 2009-2010 Navigator
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 F-150, Expedition, Explorer Sport Trac, Explorer, Mountaineer and
Navigator vehicles equipped with a 6R80 transmission may show signs of transmission fluid
leakage around the transmission bulkhead connector sleeve.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Verify the leak is present at the transmission bulkhead connector sleeve. With the vehicle in
neutral, position it on a hoist. For additional information, refer to Workshop Manual (WSM), Section
100-02.
1. Disconnect the transmission vehicle harness connector by twisting the outer shell and pulling
back on the connector.
2. Remove the transmission fluid pan and allow the transmission fluid to drain.
3. Pull the release tab and pull down on the transmission bulkhead electrical connector retainer.
4. With the release tab down, pull the connector sleeve out of the case/mechatronic assembly.
5. Lube new connector sleeve 0-rings with clean transmission fluid, then install connector sleeve
into case/mechantronic assembly.
6. Press up on the tab and lock the outer shell of the transmission bulkhead electrical connector
sleeve in place. Make sure that the locking tab is
securely locked.
7. Install the transmission fluid pan/gasket and refill transmission fluid refer to WSM, Section
307-01 for refill procedure.
NOTE
DO NOT TOUCH THE ELECTRICAL CONNECTOR PINS OR THE EXPOSED SOLENOID TABS
ON THE TRANSMISSION BULKHEAD ELECTRICAL CONNECTOR. ELECTROSTATIC
DISCHARGE MAY OCCUR AND MAY CAUSE DAMAGE TO THE TRANSMISSION CONTROL
MODULE (TCM).
NOTE
BULKHEAD CONNECTOR SLEEVES MAY COME WITH RED OR BLACK 0-RING SEALS. USE
ONLY BULKHEAD CONNECTOR SLEEVE THAT HAS BLACK 0-RING SEAL FOR THIS
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 11-3-25 > Mar
> 11 > A/T - Fluid Leaks From Bulkhead Connector > Page 4384
OPERATION DESCRIPTION TIME
110325A 2009-2010 Explorer, 1.7 Hrs.
Mountaineer, Explorer Sport Trac, And F-150: Replace Connector Sleeve Includes Time To
Remove And Install Transmission Fluid Pan (Do Not Use With Any Other Labor Operations)
110325A 2009-2010 Expedition And 1.8 Hrs.
Navigator: Replace Connector Sleeve Includes Time To Remove And Install Transmission Fluid
Pan (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7G276 D8
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-22-15 > Nov
> 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's
Wiring Harness: All Technical Service Bulletins A/T Controls - MIL ON/Various A/T Solenoid DTC's
TSB 09-22-15
11/16/09
5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION
FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR
BEFORE 8/12/2009
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or
before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with
diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related
DTCs. This may be due to water traveling down from the A/C drain into the solenoid body
connector on the left side of the transmission.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify any transmission related symptoms or transmission related DTC's that are present.
2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be
coming from the A/C drain. (Figure 1)
3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed.
4. Cut and install patch kit over the connector. (Figure 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4389
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092215A 2006-2010 Explorer, 0.4 Hr.
Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease
Connector, Install Patch (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7G391 X2
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Hydraulic Hose, Clutch > Component Information >
Tools and Equipment
Hydraulic Hose: Tools and Equipment
Clutch Line Fork
AST tool# 8008
Used for the R and R of the hydraulic clutch line from the internally mounted slave cylinder. This
tool is applicable to the following Ford vehicles with manual transmissions: 1989 and later Ford
Aerostar, Bronco II, Explorer, F150 and Ranger.
- For R and R of Hydraulic Clutch Lines
- Applicable to Ford Models with Manual Transmissions
- Steel Construction
- Black-Oxide Finish
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications
Fluid - Differential: Specifications
Motorcraft SAE 75W-140 High Performance Synthetic Rear Axle Lubricant Ford Part Number ........
..............................................................................................................................................................
................. XY-75W140-QL Ford Specification ...................................................................................
................................................................................................... WSL-M2C192-A
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair
Differential Output Shaft Bearing: Service and Repair
Stub Shaft Pilot Bearing and Seal
Removal
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Page 4402
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 Bearing Cup Remover and Slide Hammer, remove the stub shaft pilot bearing and stub
shaft pilot bearing oil seal.
1. Firmly engage the tangs of the Bearing Cup Remover 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. NOTICE: Installation of the stub shaft pilot bearing or stub shaft pilot bearing oil seal without the
correct tools can result in early stub
shaft pilot bearing or stub shaft pilot bearing oil seal failure. If the stub shaft pilot bearing becomes
cocked in the bore during installation, remove it and install a new stub shaft pilot bearing.
Place the stub shaft pilot bearing onto the Halfshaft Pilot Bearing Installer and Handle.
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 LIS17850 to avoid interference with the suspension components.
Install the stub shaft pilot bearing oil seal onto a suitable seal installer.
5. Carefully align the stub shaft pilot bearing oil seal with the housing bore and install the stub shaft
pilot bearing oil seal flush in the differential
housing.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Page 4403
6. Install the halfshaft assembly.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair
Pinion Flange: Service and Repair
Drive Pinion Flange and Drive Pinion Seal
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Page 4407
Removal
1. NOTICE: 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-in) torque wrench on the pinion nut and record the torque necessary to maintain
rotation of the drive pinion gear through several
revolutions.
NOTICE: 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.
5. Using the Drive Pinion Flange Holding Fixture 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 2-Jaw Puller, 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Page 4408
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 Drive Pinion Oil Seal Installer 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 Drive Pinion Flange Holding Fixture and Drive Pinion Flange Installer, install the pinion
flange.
7. NOTICE: 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. NOTICE: 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-in) torque wrench.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Page 4409
- 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal
Seals and Gaskets: Service and Repair Drive Pinion Flange and Drive Pinion Seal
Drive Pinion Flange and Drive Pinion Seal
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4414
Removal
1. NOTICE: 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-in) torque wrench on the pinion nut and record the torque necessary to maintain
rotation of the drive pinion gear through several
revolutions.
NOTICE: 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.
5. Using the Drive Pinion Flange Holding Fixture 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 2-Jaw Puller, remove the pinion flange.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4415
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.
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 Drive Pinion Oil Seal Installer 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 Drive Pinion Flange Holding Fixture and Drive Pinion Flange Installer, install the pinion
flange.
7. NOTICE: 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4416
installation or damage to the component may occur.
Select the new pinion nut for installation. Install and hand-tighten the pinion nut.
8. NOTICE: 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-in) 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 (V6-4.0L (2009))
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 4417
Seals and Gaskets: Service and Repair Stub Shaft Pilot Bearing and Seal
Stub Shaft Pilot Bearing and Seal
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4418
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 Bearing Cup Remover and Slide Hammer, remove the stub shaft pilot bearing and stub
shaft pilot bearing oil seal.
1. Firmly engage the tangs of the Bearing Cup Remover 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. NOTICE: Installation of the stub shaft pilot bearing or stub shaft pilot bearing oil seal without the
correct tools can result in early stub
shaft pilot bearing or stub shaft pilot bearing oil seal failure. If the stub shaft pilot bearing becomes
cocked in the bore during installation, remove it and install a new stub shaft pilot bearing.
Place the stub shaft pilot bearing onto the Halfshaft Pilot Bearing Installer and Handle.
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 LIS17850 to avoid interference with the suspension components.
Install the stub shaft pilot bearing oil seal onto a suitable seal installer.
5. Carefully align the stub shaft pilot bearing oil seal with the housing bore and install the stub shaft
pilot bearing oil seal flush in the differential
housing.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4419
6. Install the halfshaft assembly.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Specifications > General Specifications
Axle Shaft Assembly: Specifications General Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Specifications > General Specifications > Page 4425
Axle Shaft Assembly: Specifications Material
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Specifications > General Specifications > Page 4426
Axle Shaft Assembly: Specifications Torque Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Specifications > Page 4427
Axle Shaft Assembly: Description and Operation
Rear Drive Halfshafts
The rear drive halfshafts consist of the following:
- Inner 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Specifications > Page 4428
Axle Shaft Assembly: Testing and Inspection
Driveline System
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical 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. If the cause is not visually evident, verify the symptom and GO to Symptom Chart - Driveline or
GO to Symptom Chart - 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 - NVH
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 4431
Removal and Installation
1. NOTICE: 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 the halfshaft nut.
- To install, tighten to 275 Nm (203 lb-ft).
4. NOTICE: 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 Front Wheel Hub Remover, press the outboard CV joint until it is loose in the hub.
5. Remove the brake cable retainer screw.
- To install, tighten to 20 Nm (177 lb-in).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 4432
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).
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 Halfshaft Remover and Handle, disengage the inboard CV joint housing from the
differential side gear.
11. Remove the halfshaft assembly.
12. NOTICE: Do not tighten the 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: Apply the brake to keep the halfshaft from rotating.
Position the halfshaft in the hub and use the previously removed hub nut to seat the halfshaft.
- Tighten to 350 Nm (258 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 4433
- Remove and discard the hub nut.
13. NOTICE: The wheel hub nut contains a one-time locking chemical that is activated by the heat
created when it is tightened. Install and
tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always
install a new wheel hub nut after loosening or when not tightened within the specified time or
damage to the components can occur.
NOTE: Apply the brake to keep the halfshaft from rotating.
Install a new hub nut.
- Tighten to 350 Nm (258 lb-ft).
14. 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 4434
Axle Shaft Assembly: Overhaul
Halfshaft Joint
Disassembly
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 4435
1. Remove the halfshaft assembly. For additional information, refer to Halfshaft See: Removal and
Replacement.
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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 4436
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.
2. Using the Constant Velocity Joint Boot Clamp Installer, 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. For the inboard CV joint, carry out the following:
1. Position the clamp on the interconnecting shaft.
2. Position the boot on the interconnecting shaft.
3. Install the tri-lobe insert.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 4437
5. Using the Drive Pinion Oil Seal Installer, install the CV joint.
6. Install the retainer circlip.
7. 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.
8. Set the halfshaft assembled length to specifications. For additional information, refer 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 4438
9. Using the Constant Velocity Joint Boot Clamp Installer, install both boot clamps.
10. Install the halfshaft assembly. For additional information, refer to Halfshaft See: Removal and
Replacement.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front Suspension
Wheel Bearing: Service and Repair Front Suspension
Wheel Bearing and Wheel Hub
Removal and Installation
NOTICE: 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. NOTICE: 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 the new bolts 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 (159 lb-in).
5. Remove the 3 bolts and the wheel bearing and wheel hub.
- Discard the bolts.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front Suspension > Page 4443
- To install, tighten the new bolts to 122 Nm (90 lb-ft).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front Suspension > Page 4444
Wheel Bearing: Service and Repair Rear Suspension
Wheel Bearing and Wheel Hub
Removal and Installation
NOTICE: 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. For additional information, refer to Wheel Knuckle See: Steering and
Suspension/Suspension/Rear Knuckle/Service
and Repair.
2. Remove the 3 brake disc shield bolts.
- To install, tighten to 8 Nm (71 lb-in).
3. Using the Bearing Puller and a suitable press, remove the wheel hub.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front Suspension > Page 4445
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. For additional information, refer to Wheel Knuckle See: Steering and
Suspension/Suspension/Rear Knuckle/Service and
Repair.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Specifications
Axle Nut: Specifications
Front Drive Halfshaft nut.......................................................................................................................
........................................................................250 Nm (184 lb-ft)
Rear Drive Halfshaft nut.......................................................................................................................
........................................................................275 Nm (203 lb-ft)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support >
Component Information > Service and Repair
Center Support: Service and Repair
Driveshaft Center Bearing
Disassembly
NOTE: The driveshaft center bearing on driveshafts with CV joint flanges are not serviced. If the
driveshaft center bearing is worn or damaged, install a new driveshaft.
1. Remove the driveshaft. For additional information, refer to Driveshaft - Rear, Two-Piece, Four
Wheel Drive (4WD) See: Drive/Propeller
Shaft/Service and Repair/Removal and Replacement/Driveshaft - Rear, Two-Piece or Driveshaft Rear, Two-Piece, Rear Wheel Drive (RWD) See: Drive/Propeller Shaft/Service and
Repair/Removal and Replacement/Driveshaft - Rear, Two-Piece.
2. NOTICE: 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.
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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support >
Component Information > Service and Repair > Page 4454
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.
6. NOTE: Install the new center bearing with the 3 bend tabs and dust seal lip facing the front of the
vehicle.
To install, reverse the removal process.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Description and Operation
Drive/Propeller Shaft: Description and Operation
Driveshaft
The driveshafts consist of the following:
- U-joint flanges
- U-joints
- Nylon thrust washers, located at each base of the bearing cup, which control end play, position
the needle bearings and improve grease movement
- Lubed-for-life design and require no lubrication
- CV joint flanges
- CV joints
- Slip-yoke
- Slip-joint boots
- Traditional welded-on balance weights
Vehicles have the following types of driveshafts:
- One-piece rear driveshaft with 2 U-joints and a front slip-yoke
- One-piece front driveshaft with a front U-joint, a slip-yoke and a rear CV joint
- Two-piece rear driveshaft with 3 U-joints
- Two-piece rear driveshaft with 2 CV joints and one U-joint
NOTE: Whenever the vehicle is raised on a hoist, inspect the U-joint slip-yoke boot for rips or
holes. Install new if required.
NOTE: All driveshafts are balanced. If undercoating the vehicle, protect the driveshaft and U-joints
to prevent application of any undercoating material.
The driveshaft transfers input from the transmission or transfer case to the front or rear drive axles.
The driveshaft is composed of the U-joints or CV joints, connecting shafts and attaching yokes. The
driveshaft accommodates the change in length in the driveline system by sliding on the
transmission output shaft with a slip-yoke or a slip-joint which is integral to the driveshaft. The
shafts vary in diameter, length, number of coupling shafts and U-joints or CV joints, depending on
vehicle application. The U-joints and CV joints allow the driveshaft to rotate smoothly through the
changing angles between the transmission output shaft and the driveshaft, plus the changes
between the rear axle pinion angle and the driveshaft. On 2-wheel drive vehicles, power is
transmitted through the transmission to the driveshaft and then to the rear axle. On All-Wheel Drive
(AWD) vehicles, power is transmitted from the transmission to the front and rear axles through the
transfer case.
The engine angle is built into the engine mounts. If the driveshaft angles are out of specification,
the engine mounts must be inspected for damage.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Procedures
Drive/Propeller Shaft: Procedures
Driveline Angle Measurement
Driveline Angle Measurement
NOTE: This procedure does not apply to CV joints, flex couplers or double cardan joints that are
used in some driveshafts. This check is for single-cross and roller-style joints found in the
driveshafts.
NOTE: Prior to checking driveline angularity, inspect the U-joints for correct operation.
NOTE: An incorrect driveline angle can cause a vibration or shudder.
NOTE: Driveline angularity is the angular relationship between the engine crankshaft, the
driveshaft and the rear axle pinion. Factors determining driveline angularity include ride height, rear
spring and engine mounts.
All vehicles
1. Carry out the following preliminary setup steps:
- Inspect the U-joints for correct operation.
- Park the vehicle on a level surface such as a drive-on hoist, or back onto a front end alignment
rack.
- Verify the curb position ride height is within specifications with the vehicle unloaded and all of the
tires are inflated to their normal operating pressures.
- Calibrate the Anglemaster II Driveline Inclinometer/Protractor by placing it on a clean, flat level of
the frame rail and press the ALT-ZERO button.
Vehicles with flat-flanged, split-pin or slip-flanged U-joints
2. NOTE: If equipped, remove the snap ring to allow access to the base of the U-joint cup. Make
sure the Anglemaster II Driveline
Inclinometer/Protractor is seated against the U-joint cup.
NOTE: Rotate the driveshaft until the flange U-joint cup is parallel with the floor. This will simplify
taking measurements.
To check the U-joint operating angle, install the Anglemaster II Driveline Inclinometer/Protractor.
Check and record the flange angle as angle A.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Procedures > Page 4460
3. Using the Anglemaster II Driveline Inclinometer/Protractor, measure the slope of the connecting
component. Record the measurement of the
component angle as angle B.
Multiple piece driveshafts
4. NOTE: Repeat this step for each center support bearing on the driveshaft.
NOTE: It is not necessary to remove the U-joint snap ring, if equipped, for these measurements.
Using the Anglemaster II Driveline Inclinometer/Protractor, measure the slope of the components in
front and behind the center support bearing U-joint in the area indicated. Record the front
component as angle A and the rear component as angle B.
All vehicles
5. NOTE: When 2 connected components slope in the same direction, subtract the smallest
number from the larger number to find the U-joint
operating angle. When 2 connected components slope in the opposite direction, add the
measurements to find the U-joint operating angle.
Calculate the difference in the slope of the components to determine the U-joint operating angle.
- The U-joint operating angle is the angle formed by 2 yokes connected by a cross and bearing kit.
Ideally, the operating angles on each connection of the driveshaft must: be equal or within one degree of each other.
- have a 3 degree maximum operating angle.
- have at least one-half of one degree continuous operating angle.
6. If the angle is not within specifications, repair or adjust to obtain the correct angle. Inspect the
engine mounts, transmission mounts, center support
bearing mounting, rear suspension, rear axle, rear axle mounting or the frame for wear or damage.
Driveshaft Runout and Balancing
Driveshaft Runout and Balancing
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Procedures > Page 4461
Driveshaft Inspection
NOTE: Driveline vibration exhibits a higher frequency and lower amplitude than high-speed shake.
Driveline vibration is directly related to the speed of the vehicle and is noticed at various speeds.
Driveline vibration can be perceived as a tremor in the floorpan or heard as a rumble, hum or
boom.
NOTE: Refer to Specifications for all runout specifications.
1. NOTE: Do not make any adjustments before carrying out a road test. Do not change the tire
pressure or the vehicle load.
Carry out a visual inspection of the vehicle. Operate the vehicle and verify the condition by
reproducing it during the road test.
- The concern should be directly related to vehicle road speed, not affected by acceleration or
deceleration or could not be reduced by coasting in NEUTRAL.
2. With the vehicle in NEUTRAL, position it on a hoist.
- The driveshaft should be kept at an angle equal to or close to the curb-weighted position. Use a
twin-post hoist or a frame hoist with jackstands.
3. Inspect the driveshaft for damage, undercoating or incorrectly seated U-joints. Rotate the
driveshaft slowly by hand and feel for binding or end
play in the U-joint trunnions. Remove the driveshaft. Inspect the slip yoke splines for any galling,
dirt, rust or incorrect lubrication. Clean the driveshaft or install new U-joints as necessary. Install a
new driveshaft if damaged. After any corrections or new components are installed, recheck for the
vibration at the road test speed. If the vibration is gone, test drive the vehicle.
- If the vibration persists or the driveshaft passes visual inspection, measure the driveshaft runout.
Driveshaft Runout
1. Install the Dial Indicator Gauge with Holding Fixture. Rotate the driveshaft by turning the axle
and measure the runout at the front, the center and
the rear of the driveshaft. If the runout exceeds 1 mm (0.040 in) at the front or center, install a new driveshaft.
- If the front and center is within 1 mm (0.040 in), but the rear runout is not, index-mark the rear
runout high point and proceed to Step 2.
- If the runout is within 1 mm (0.040 in) at all points, recheck for vibration at road test speed. If the
vibration persists, balance the driveshaft. For additional information, refer to Driveshaft Balancing in
this procedure.
2. NOTE: Circular pinion flanges can be turned in 90 degree or one-fourth increments. Half-round
pinion flanges are limited to 2 positions.
Index-mark the driveshaft to the pinion flange. Disconnect the driveshaft and rotate it 180 degrees.
Reconnect the driveshaft. Recheck the runout at the rear of the driveshaft.
- If the runout is still over specification, mark the high point and proceed to Step 3.
- If the runout is within specification, check for the vibration at the road test speed. If the vibration is
still present, balance the driveshaft. For additional information, refer to Driveshaft Balancing in this
procedure.
3. Excessive driveshaft runout can originate in the driveshaft itself or from the pinion flange. To find
the source, compare the 2 high points
previously determined.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Procedures > Page 4462
- If the index marks are close together, within 25 mm (1 in), the driveshaft is eccentric. Install a new
driveshaft.
- If the marks are on opposite sides of the driveshaft, 180 degrees apart, the slip yoke or pinion
flange is responsible. Check the pinion flange runout. If the pinion flange runout exceeds
specifications, a bent pinion is indicated.
- If the pinion flange and pinion runouts are within specifications, road test and check for the
vibration at the road test speed. If the vibration persists, balance the driveshaft. For additional
information, refer to Driveshaft Balancing in this procedure.
Driveshaft Balancing - Using the Mastertech(R) Series MTS 4000 Driveline Balance and NVH
Analyzer (Vetronix)
All vehicles
1. Install the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix) to
the vehicle.
2. Working under the vehicle, install an accelerometer. The accelerometer can be attached and
mounted near either the transmission or differential
end of the driveshaft.
3. Clean an area of the driveshaft and install the reflective tape, then install the photo-tachometer
sensor. The sensor should be placed at
approximately a 20-degree angle from perpendicular to the surface of the reflective tape. Make
sure the sensor does not get moved during the balance procedure.
1. Reflective tape.
2. Photo-tachometer sensor.
4. Using the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix), run
a driveshaft balance test with the driveshaft
unmodified.
Vehicles with tapped pinion flanges
5. Label the tapped holes in the pinion flange numerically, starting at the top hole as 1. Mark the
remaining holes 2, 3 and 4. Label in the direction of
rotation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Procedures > Page 4463
6. Using the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix), run
a second test with the 12 mm (0.47 in) test
weight set screw in the No. 1 hole, previously marked on the pinion flange.
7. Remove the test weight, then install the weight combination directed by the Mastertech(R)
Series MTS 4000 Driveline Balance and NVH
Analyzer (Vetronix).
Vehicles without tapped pinion flanges
8. Using the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix), run
a second test with a test weight. Using a metal
band, secure the test weight to the end of the driveshaft. The weight should be placed at the end of
the driveshaft tube, as close to the tube-to-yoke weld seam as possible. Mark the location of the
test weight on the driveshaft, as shown in the figure below.
1. Test weight.
2. Tube-to-yoke weld seam.
3. Driveshaft pinion flange.
- Select the test weight based on driveshaft size. Larger driveshafts use 10 g (0.353 oz). Smaller
driveshafts use 5 g (0.176 oz).
9. Remove the test weight, then install the recommended weight at the position directed by the
Mastertech(R) Series MTS 4000 Driveline Balance
and NVH Analyzer (Vetronix). Using a metal band and epoxy, secure the test weight to the
driveshaft, as shown in the figure below.
1. Test weight.
2. Measure in this direction.
3. Driveshaft diameter.
4. Directional rotation.
5. Balance weight relative to test weight centerline.
- The results are displayed with respect to the location to where the test weight was placed.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Procedures > Page 4464
All vehicles
10. Using the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix), run
a third test to verify the repair.
Driveshaft Balancing - Hose Clamp Method
1. Install 1 or 2 hose clamps on the driveshaft, near the rear. Position of the hose clamp head(s)
can be determined through trial and error.
2. Mark the rear of the driveshaft into 4 approximately equal sectors and number the marks 1
through 4. Install a hose clamp on the driveshaft with its
head at position No. 1, as shown in the figure below. Check for vibration at road speed. Recheck
with the clamp at each of the other positions to find the position that shows minimum vibration. If 2
adjacent positions show equal improvement, position the clamp head between them.
3. If the vibration persists, add a second clamp at the same position and recheck for vibration.
4. If no improvement is noted, rotate the clamps in opposite directions, equal distances from the
best position determined in Step 2. Separate the
clamp heads about 13 mm (1/2 in) and recheck for vibration at the road speed.
5. Repeat the process with increasing separation until the best combination is found or the vibration
is reduced to an acceptable level.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Procedures > Page 4465
Drive/Propeller Shaft: Removal and Replacement
Driveshaft - Rear, One-Piece
Driveshaft - Rear, One-Piece, 4.0L SOHC
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.
3. Index-mark the driveshaft flange to the pinion flange to maintain driveshaft balance.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Procedures > Page 4466
4. NOTE: If new pinion flange bolts are not available and the originals are not damaged, they can
be reused if the threads are coated with threadlock
and sealer.
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.
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 cross pattern.
NOTE: If new driveshaft flange bolts are not available, coat the threads of the original driveshaft
flange bolts with threadlock and sealer.
To install, reverse the removal procedure.
Driveshaft - Rear, Two-Piece
Driveshaft - Rear, Two-Piece, Rear Wheel Drive (RWD)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Procedures > Page 4467
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.
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. NOTE: If new flange bolts are not available and the originals are not damaged, they can be
reused if the threads are coated with threadlock and
sealer.
Remove and discard the 4 driveshaft flange bolts from the transmission output shaft flange.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Procedures > Page 4468
- To install, tighten the 4 new bolts to 112 Nm (83 lb-ft).
All vehicles
7. NOTE: If new flange bolts are not available and the originals are not damaged, they can be
reused if the threads are coated with threadlock and
sealer.
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.
Driveshaft Slip Yoke Boot
Driveshaft Slip Yoke Boot
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Procedures > Page 4469
Removal
1. Remove the driveshaft. For additional information, refer to Driveshaft - Rear, One-Piece, 4.6L
(3V) See: Driveshaft - Rear, One-Piece.
2. Index-mark the driveshaft on both sides of the driveshaft slip yoke boot.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Procedures > Page 4470
3. Using the Keystone Clamp Installer, install the new driveshaft slip yoke boot.
4. Install the driveshaft. For additional information, refer to Driveshaft - Rear, One-Piece, 4.6L (3V)
See: Driveshaft - Rear, One-Piece.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft Universal Joint - Snap Ring Type
Universal Joint: Service and Repair Driveshaft Universal Joint - Snap Ring Type
Driveshaft Universal Joint - Snap Ring Type
Disassembly and Assembly
NOTE: The front driveshaft CV joint is not repairable.
1. Remove the driveshaft. For additional information, refer to Driveshaft - Rear, One-Piece, 4.0L
SOHC See: Drive/Propeller Shaft/Service and
Repair/Removal and Replacement/Driveshaft - Rear, One-Piece, Driveshaft - Rear, One-Piece,
4.6L (3V) See: Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Driveshaft Rear, One-Piece or Driveshaft - Front .
2. Index-mark the components at the U-joints for reassembly.
3. Remove and discard the 4 snap rings.
4. Position the driveshaft in the C-Frame and Screw Installer/Remover. Using the C-Frame and
Screw Installer/Remover, press out a bearing cup.
5. If necessary, use a pair of pliers to remove the bearing cup if it cannot be pressed all the way
out.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft Universal Joint - Snap Ring Type > Page
4475
6. Rotate the driveshaft and press on the spider to remove the remaining bearing cup.
7. Remove the driveshaft flange.
8. Position the driveshaft in the C-Frame and Screw Installer/Remover. Using the C-Frame and
Screw Installer/Remover, press out the bearing cup.
9. If necessary, use a pair of pliers to remove the bearing cup if it cannot be pressed all the way
out.
10. Rotate the driveshaft and press on the spider to remove the remaining bearing cup.
11. Remove the spider.
12. NOTE: Clean the bearing cup bores.
NOTE: Check the U-joints for freedom of movement. If binding, strike the driveshaft flange with a
brass or plastic hammer. Do not strike the U-joint.
To assemble, reverse the disassembly procedure.
- Use the yellow snap rings supplied in the kit to install the U-joint. If difficulty is encountered with
the yellow snap rings, install the black snap rings, as required.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft Universal Joint - Snap Ring Type > Page
4476
Universal Joint: Service and Repair Driveshaft Universal Joint - Stake Type
Driveshaft Universal Joint - Stake Type
1. The staked driveshaft U-joints are not serviced separately within the warranty period. Install a
new driveshaft if worn or damaged.
2. U-joint service kits with instructions are available through a Ford authorized dealer for a high
mileage repair.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
Install the flexplate. Tighten the 8 new bolts in the sequence shown in 3 stages. Stage 1: Tighten to
..............................................................................................................................................................
........................13 Nm (115 lb-in). Stage 2: Tighten to.........................................................................
................................................................................................................50 Nm (37 lb-ft). Stage 3:
Tighten an additional............................................................................................................................
.....................................................90 degrees.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair >
Procedures
Flex Plate: Procedures
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair >
Procedures > Page 4482
Flex Plate: Removal and Replacement
Flexplate
Removal
1. Remove the transmission.
2. Remove the 8 bolts and the flexplate.
- Discard the bolts.
Installation
1. NOTE: New flexplate bolts must be installed. They are a torque-to-yield design and cannot be
reused.
Install the flexplate. Tighten the 8 new bolts in 3 stages in the sequence shown.
- Stage 1: Tighten to 13 Nm (115 lb-in).
- Stage 2: Tighten to 50 Nm (37 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
2. Install the transmission.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
Transmission Control Indicator Lamp (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Description and
Operation
Power Take-Off: Description and Operation
Engine Control Components
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 (I/M) test, operate the vehicle with
the PTO disengaged long enough to successfully complete the OBD Monitors.
PTO Circuits Description
The three 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 when the operator is requesting additional engine RPM for PTO
operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: >
09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: >
09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4501
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: >
09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4502
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2
Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4508
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4509
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 Other Service Bulletins
for Control 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 (V6-4.0L (2009))
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 Other Service Bulletins
for Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 4515
^ 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 (V6-4.0L (2009))
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 Other Service Bulletins
for Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 4516
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 (V6-4.0L (2009))
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 Other Service Bulletins
for Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 4522
^ 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 (V6-4.0L (2009))
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 Other Service Bulletins
for Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 4523
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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation
Brake Switch - TCC: Description and Operation
Engine Control Components
Brake Pedal Position (BPP) Switch
The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal
to the PCM indicating the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Typical BPP Switch
Typical BPP Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation
Transmission Mode Switch: Description and Operation
Engine Control Components
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.
Typical Transmission Control Switch (TCS) (Column Shift)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS) (Floor Shift)
Typical Transmission Control Switch (TCS)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission
Control Switch (TCS)
Transmission Mode Switch: Service and Repair Transmission Control Switch (TCS)
External Controls
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) is a momentary contact switch located on the selector
lever knob. Pushing the TCS will either disengage or engage the overdrive function of the
transmission. If OVERDRIVE is disengaged, the message Overdrive (O/D) OFF will illuminate on
the Instrument Cluster (IC).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission
Control Switch (TCS) > Page 4534
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch
Transmission Control (TC) Switch
Removal
1. Remove the selector lever knob. For additional information, refer to Selector Lever Knob See:
Automatic Transmission/Transaxle/Shifter
A/T/Service and Repair/Selector Lever Knob.
2. Remove the Transmission Control Switch (TCS) from the knob.
Installation
1. Install the TCS into the selector lever knob.
2. Install the selector lever knob. For additional information, refer to Selector Lever Knob See:
Automatic Transmission/Transaxle/Shifter
A/T/Service and Repair/Selector Lever Knob.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4538
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4539
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4540
Transmission Position Switch/Sensor: Adjustments
5R55S
Transmission Range (TR) Sensor Adjustment
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 Transmission Range (TR) sensor connector.
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable end from the manual control lever.
6. Remove the manual control lever nut and the manual control lever.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4541
7. Loosen but do not remove the TR sensor screws.
8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence.
- Tighten to 8 Nm (71 lb-in).
9. Install the manual control lever and manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
11. Reconnect the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4542
12. Reinstall the rubber boot over the TR 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 (V6-4.0L (2009))
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 4543
Transmission Position Switch/Sensor: Service and Repair
5R55S
Digital Transmission Range (TR) Sensor
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
3. Move the TR sensor connector boot back to gain access to the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4544
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable from the manual control lever.
6. Remove the manual control lever nut.
7. Remove the TR sensor.
Installation
1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to
prevent damage to the sensor.
Install the TR sensor and loosely install the TR sensor screw and washer (2 required).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4545
2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual control lever must be in the NEUTRAL position.
Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence. Tighten to 8 Nm (71 lb-in).
3. Install the manual control lever and the manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
5. Connect the TR sensor connector.
6. Move the TR sensor connector boot back over the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4546
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 (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4551
Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4552
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4553
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Output Shaft Speed (OSS)
Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Output Shaft Speed (OSS)
Sensor > Page 4556
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Output Shaft Speed (OSS)
Sensor > Page 4557
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft
Speed (TSS) Sensor
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft
Speed (TSS) Sensor > Page 4560
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the Turbine Shaft Speed (TSS) sensor 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft
Speed (TSS) Sensor > Page 4561
Installation
All vehicles
1. Inspect the TSS O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the TSS sensor connector.
3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever bracket and selector lever bracket screws.
- Tighten to 40 Nm (30 lb-ft).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft
Speed (TSS) Sensor > Page 4562
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft
Speed (TSS) Sensor > Page 4563
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft
Speed (TSS) Sensor > Page 4564
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
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 connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft
Speed (TSS) Sensor > Page 4565
9. Remove the OSS sensor.
1. Remove the OSS sensor screw.
2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
All vehicles
1. Inspect the OSS O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the OSS sensor connector.
3. Connect the HO2S connector to the transmission case.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft
Speed (TSS) Sensor > Page 4566
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever cable bracket and selector lever cable bracket
screws.
- 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.
7. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
8. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft
Speed (TSS) Sensor > Page 4567
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft
Speed (TSS) Sensor > Page 4568
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft
Speed (TSS) Sensor > Page 4569
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the intermediate shaft speed sensor 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft
Speed (TSS) Sensor > Page 4570
Installation
All vehicles
1. Inspect the O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the intermediate shaft speed sensor connector.
3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever cable bracket and selector lever cable bracket
screws.
- Tighten to 40 Nm (30 lb-ft).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft
Speed (TSS) Sensor > Page 4571
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal
1. Remove the front floor console.
2. Disconnect the Brake Shift Interlock Actuator (BSIA) electrical connector.
3. Remove the screw and the BSIA.
Installation
1. Install the BSIA and the screw.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4578
2. Connect the BSIA electrical connector.
3. Install the front floor console.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
Transmission Control Indicator Lamp (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift
Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift > Page 4594
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline
Bump/Harsh 1-2 Shift > Page 4595
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift
Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2
Shift
TSB 09-18-10
09/21/09
DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT
BEFORE 10/1/2008
FORD: 2009 Explorer Sport Trac, Explorer
MERCURY: 2009 Mountaineer
ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80
transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below
15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve
these conditions.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and
start a session, identify (ID) vehicle.
2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration
using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD.
Calibration files may also be obtained at the website.
The TCM cannot be independently reprogrammed. Reprogram using the programmable module
installation (PMI) function to ensure that engine and transmission calibrations are updated to the
latest level simultaneously.
In some cases it maybe helpful to
^ Disconnect the TCM connector.
^ Start a new IDS session.
^ Perform PMI on the PCM.
^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the
prompts.
a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is
complete.
b. Select the following from the IDS tool:
(1) Toolbox.
(2) Powertrain.
(3) OBD Test Modes.
(4) Mode 9 Vehicle Information.
(5) TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift > Page 4601
(3) Choose Reset KAM.
(4) Choose TCM.
b. Using PDS:
(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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1600-2000 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 ten (10) seconds.
g. Repeat steps (d-f) three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING ARE 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
091810A 2009 Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac 6R80 Transmission: Reprogram The PCM And TCM, Includes
Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift > Page 4602
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Description
and Operation
Brake Switch - TCC: Description and Operation
Engine Control Components
Brake Pedal Position (BPP) Switch
The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal
to the PCM indicating the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Typical BPP Switch
Typical BPP Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Description and Operation
Transmission Mode Switch: Description and Operation
Engine Control Components
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.
Typical Transmission Control Switch (TCS) (Column Shift)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS) (Floor Shift)
Typical Transmission Control Switch (TCS)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 >
Service and Repair > Transmission Control Switch (TCS)
Transmission Mode Switch: Service and Repair Transmission Control Switch (TCS)
External Controls
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) is a momentary contact switch located on the selector
lever knob. Pushing the TCS will either disengage or engage the overdrive function of the
transmission. If OVERDRIVE is disengaged, the message Overdrive (O/D) OFF will illuminate on
the Instrument Cluster (IC).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 >
Service and Repair > Transmission Control Switch (TCS) > Page 4613
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch
Transmission Control (TC) Switch
Removal
1. Remove the selector lever knob. For additional information, refer to Selector Lever Knob See:
Automatic Transmission/Transaxle/Shifter
A/T/Service and Repair/Selector Lever Knob.
2. Remove the Transmission Control Switch (TCS) from the knob.
Installation
1. Install the TCS into the selector lever knob.
2. Install the selector lever knob. For additional information, refer to Selector Lever Knob See:
Automatic Transmission/Transaxle/Shifter
A/T/Service and Repair/Selector Lever Knob.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4617
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4618
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4619
Transmission Position Switch/Sensor: Adjustments
5R55S
Transmission Range (TR) Sensor Adjustment
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 Transmission Range (TR) sensor connector.
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable end from the manual control lever.
6. Remove the manual control lever nut and the manual control lever.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4620
7. Loosen but do not remove the TR sensor screws.
8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence.
- Tighten to 8 Nm (71 lb-in).
9. Install the manual control lever and manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
11. Reconnect the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4621
12. Reinstall the rubber boot over the TR 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 (V6-4.0L (2009))
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 4622
Transmission Position Switch/Sensor: Service and Repair
5R55S
Digital Transmission Range (TR) Sensor
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
3. Move the TR sensor connector boot back to gain access to the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4623
4. Disconnect the TR sensor connector.
5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable from the manual control lever.
6. Remove the manual control lever nut.
7. Remove the TR sensor.
Installation
1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to
prevent damage to the sensor.
Install the TR sensor and loosely install the TR sensor screw and washer (2 required).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4624
2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual control lever must be in the NEUTRAL position.
Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an
alternating sequence. Tighten to 8 Nm (71 lb-in).
3. Install the manual control lever and the manual control lever nut.
- Tighten to 48 Nm (35 lb-ft).
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable end onto the manual control lever ball stud.
5. Connect the TR sensor connector.
6. Move the TR sensor connector boot back over the TR sensor connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4625
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 (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4630
Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4631
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4632
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Output Shaft Speed (OSS) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Output Shaft Speed (OSS) Sensor > Page 4635
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Output Shaft Speed (OSS) Sensor > Page 4636
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4639
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the Turbine Shaft Speed (TSS) sensor 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4640
Installation
All vehicles
1. Inspect the TSS O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the TSS sensor connector.
3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever bracket and selector lever bracket screws.
- Tighten to 40 Nm (30 lb-ft).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4641
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4642
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4643
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
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 connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4644
9. Remove the OSS sensor.
1. Remove the OSS sensor screw.
2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
All vehicles
1. Inspect the OSS O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the OSS sensor connector.
3. Connect the HO2S connector to the transmission case.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4645
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever cable bracket and selector lever cable bracket
screws.
- 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.
7. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
8. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4646
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4647
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor
5R55S
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.
3. Disconnect the front driveshaft from the front differential.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4648
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 Transmission Range (TR) sensor
connector boot, then sliding the selector lever cable shield away from the TR sensor connector
boot.
6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the intermediate shaft speed sensor 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 (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4649
Installation
All vehicles
1. Inspect the O-ring seal for damage. Install a new O-ring 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 (124 lb-in).
2. Connect the intermediate shaft speed sensor connector.
3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the
selector lever cable bracket.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to
make sure that the selector cable end is correctly installed onto the manual control lever ball stud.
Install the selector lever cable, selector lever cable bracket and selector lever cable bracket
screws.
- Tighten to 40 Nm (30 lb-ft).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4650
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts.
- Tighten to 30 Nm (22 lb-ft).
7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap
bolts.
- Tighten to 19 Nm (168 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block >
Component Information > Locations > Page 4656
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems >
Acceleration/Deceleration Sensor > Component Information > Service and Repair
Acceleration/Deceleration Sensor: Service and Repair
Stability Control Sensor Cluster
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems >
Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 4660
- To install, tighten to 7 Nm (62 lb-in).
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic
Connector - ABS > Component Information > Locations
Diagnostic Connector - ABS: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic
Connector - ABS > Component Information > Locations > Page 4664
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic
Connector - ABS > Component Information > Locations > Page 4665
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations
Electronic Brake Control Module: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations > Page 4669
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations > Page 4670
Electronic Brake Control Module: Diagrams
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations > Page 4671
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations > Page 4672
Electronic Brake Control Module: Service and Repair
Anti-Lock Brake System (ABS) Module
Removal and Installation
NOTICE: 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. See: Powertrain
Management/Computers and Control Systems/Information Bus/Testing and
Inspection/Programming and Relearning
1. Remove the Hydraulic Control Unit (HCU). For additional information, refer to Hydraulic Control
Unit (HCU) See: Hydraulic Control Assembly
- Antilock Brakes/Service and Repair.
2. Remove the 4 screws and the ABS module.
- To install, tighten to 2 Nm (18 lb-in).
3. NOTICE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Hydraulic Control Unit (HCU)
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Page 4676
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. For additional information, consult the product Material
Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious
personal injury.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
1. With the vehicle in NEUTRAL, position it on a hoist.
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.
Disconnect the master cylinder primary and secondary brake tube-to-Hydraulic Control Unit (HCU)
fittings and position both brake tubes aside.
- To install, tighten to 25 Nm (18 lb-ft).
5. NOTE: The brake tubes must be installed in the same location as removed.
Disconnect the 4 brake tube-to-HCU extension tube fittings.
- To install, tighten to 18 Nm (159 lb-in).
6. Remove the 3 HCU bracket-to-frame nuts and the HCU assembly.
- To install, tighten the nuts to 23 Nm (17 lb-ft).
7. NOTE: The brake tubes must be installed in the same location as removed.
Disconnect the 4 HCU extension tube-to-HCU fittings.
- To install, tighten to 18 Nm (159 lb-in).
8. Remove the 2 HCU bracket-to-HCU extension tube retainer nuts and the extension tube retainer
assembly.
- To install, tighten the nuts to 9 Nm (80 lb-in).
9. Remove the HCU bracket-to-HCU bolt and the HCU bracket.
- To install, tighten the bolts to 9 Nm (80 lb-in).
10. To install, reverse the removal procedure.
- Bleed the brake system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 screws and the steering wheel rotation sensor.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Locations > Page 4683
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Locations > Page 4684
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.
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 (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4689
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4690
Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4691
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4692
Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Rear
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4693
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4694
Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Rear
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4695
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 4698
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 4699
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 4700
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
- To install, tighten to 8 Nm (71 lb-in).
4. Remove the wheel speed sensor harness pin-type retainers.
5. Remove the wheel speed sensor bolt and the wheel speed sensor.
- To install, tighten the bolt to 17 Nm (150 lb-in).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4703
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.
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 (V6-4.0L (2009))
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 4704
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring - Rear
Wheel Speed Sensor Ring - Rear
Removal
1. Remove the rear halfshaft.
2. Using a suitable driver, remove the ABS wheel speed sensor ring.
Installation
1. Install the new ABS wheel speed sensor and the Wheel Speed Sensor Ring Installers on the
halfshaft as shown.
2. Using the Wheel Speed Sensor Ring Installers, install the ABS wheel speed sensor ring as
shown.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4705
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Component Bleeding
Brake Bleeding: Service and Repair Component Bleeding
Master Cylinder
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
NOTE: When a new brake master cylinder is installed, or the system is 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.
3. Fill the brake master cylinder reservoir with clean, specified brake fluid.
4. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air
bubbles.
5. Remove the short brake tubes and install the brake outlet tubes.
6. 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,
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Component Bleeding > Page 4710
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 brake tube fittings to specifications. For additional information, refer to
Specifications.
7. Bleed the brake system, refer to Brake System Bleeding See: Brake System Bleeding.
Brake Caliper
Component Bleeding
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
1. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was
disconnected or installed new.
Remove the 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 at least 2 times 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.
4. Remove the rubber hose and tighten the bleeder screw to specifications. For additional
information, refer to Specifications.
- Install the bleeder screw cap.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Component Bleeding > Page 4711
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Component Bleeding > Page 4712
Brake Bleeding: Service and Repair Brake System Bleeding
Brake System Bleeding
Pressure
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any
components upstream of the HCU are installed new.
NOTE: Pressure bleeding the brake system is preferred to manual bleeding.
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: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the equipment 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: Make sure the bleeder tank contains enough clean, specified brake fluid to complete the
bleeding operation.
Remove the RH rear 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Component Bleeding > Page 4713
4. Open the valve on the bleeder tank.
- Set pressure to 207-345 kPa (30-50 psi).
5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then
tighten the RH rear bleeder screw and remove the
rubber hose. Tighten to specifications. For additional information, refer to Specifications.
- Install the bleeder screw cap.
6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front
bleeder screw ending with the LH front bleeder
screw.
7. Release the bleeder tank pressure and close the bleeder tank valve. Remove the tank hose from
the adapter and remove the adapter from the brake
fluid reservoir.
Manual
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any
components upstream of the HCU are installed new.
NOTE: Pressure bleeding the brake system is preferred to manual bleeding.
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. Remove the bleeder screw cap and place a box-end wrench on the RH rear bleeder screw.
Attach a rubber drain hose to the RH rear bleeder screw
and submerge the free end of the hose in a container partially filled with clean, specified brake
fluid.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Component Bleeding > Page 4714
3. Have an assistant pump the brake pedal at least 3 times and then hold firm pressure on the
brake pedal.
4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the
RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
5. Remove the rubber hose and tighten the bleeder screw to specifications. For additional
information, refer to Specifications.
- Install the bleeder screw cap.
6. Repeat Steps 2 through 5 for the LH rear, RH front and LH front bleeder screws in this order.
Hydraulic Control Unit (HCU)
NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any
components upstream of the HCU are installed new.
NOTE: Pressure bleeding the brake system is preferred to manual bleeding.
1. Follow the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system.
2. Connect the scan tool and follow the ABS Service Bleed instructions.
3. Repeat the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Brake Pedal and Bracket
Brake Pedal Assy: Service and Repair Brake Pedal and Bracket
Brake Pedal and Bracket
NOTE: Adjustable pedals shown, fixed pedals similar.
Removal
1. NOTICE: 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.
2. If equipped, remove the speed control deactivator switch.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Brake Pedal and Bracket > Page 4719
3. NOTE: If equipped with adjustable pedals, when removing the adjustable pedal assembly, make
sure the pedals are adjusted to the full rearward
position.
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.
4. Disconnect the brake booster rod from the brake pedal and position aside.
5. If equipped with power adjustable pedals, disconnect the adjustable pedal motor electrical
connector.
6. If equipped with adjustable pedals, disconnect the accelerator pedal motor electrical connector.
7. Remove and discard the 2 brake pedal bracket bolts.
8. Remove and discard the 4 brake booster nuts.
9. Position the brake master cylinder and brake booster assembly forward to allow the brake pedal
assembly to clear the studs.
10. Remove the 3 accelerator pedal bracket nuts.
11. Remove the 2 steering column opening cover screws and the steering column opening cover
panel.
12. NOTICE: 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.
NOTE: Use a steering wheel holding device (such as Hunter(R) 28-75-1 or equivalent).
Using a suitable holding device, hold the steering wheel in the straight-ahead position.
13. Remove the steering column shaft bolt and disconnect the steering column shaft from the
steering column.
14. 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).
4. Install the 2 new brake pedal bracket bolts.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Brake Pedal and Bracket > Page 4720
- 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. NOTICE: 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. If equipped, install the speed control deactivator switch.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Brake Pedal and Bracket > Page 4721
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 (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling
Noise Over Bumps
Brake Caliper: Customer Interest Brakes - Rear Brake Rattling Noise Over Bumps
TSB 09-22-13
11/16/09
REAR BRAKE RATTLE OVER BUMPS
FORD: 2007-2010 Explorer Sport Trac, Explorer
MERCURY: 2007-2010 Mountaineer
This article supersedes TSB 7-24-6 to update the vehicle model years covered.
ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a
rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do
not incorporate an anti-rattle clip.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
To repair the rattle noise perform the following:
1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04.
2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section
206-04.
3. Support the caliper to prevent damage to the brake line. (Figure 1)
4. Remove the outer and inner brake pad and discard pads.
5. Remove the brake pad slippers from the caliper rails and discard.
6. Clean the caliper rails with a wire brush.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4731
7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the
underside of the brake pad slippers. (Figure 2)
8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to
the upper caliper rail. The larger brake pad slipper is
attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3)
9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers.
10. Remove the caliper pin sleeves and rubber boots.
11. Install new pin caliper boots.
12. Place caliper slide grease into the pin sleeve boots.
13. Install caliper slide pin into the rubber boots.
14. Clean any excess grease off of caliper.
15. Install inner and outer brake pads.
NOTE
THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL
BACKING PLATE.
16. Install brake caliper as per WSM, Section 206-04.
17. Repeat steps 2-16 on the other side.
18. Install the rear tires as per the WSM, Section 204-04.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4732
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092213A 2007-2010 Explorer, 0.8 Hr.
Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2200 07
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear
Brake Rattling Noise Over Bumps
Brake Caliper: All Technical Service Bulletins Brakes - Rear Brake Rattling Noise Over Bumps
TSB 09-22-13
11/16/09
REAR BRAKE RATTLE OVER BUMPS
FORD: 2007-2010 Explorer Sport Trac, Explorer
MERCURY: 2007-2010 Mountaineer
This article supersedes TSB 7-24-6 to update the vehicle model years covered.
ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a
rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do
not incorporate an anti-rattle clip.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
To repair the rattle noise perform the following:
1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04.
2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section
206-04.
3. Support the caliper to prevent damage to the brake line. (Figure 1)
4. Remove the outer and inner brake pad and discard pads.
5. Remove the brake pad slippers from the caliper rails and discard.
6. Clean the caliper rails with a wire brush.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4738
7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the
underside of the brake pad slippers. (Figure 2)
8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to
the upper caliper rail. The larger brake pad slipper is
attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3)
9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers.
10. Remove the caliper pin sleeves and rubber boots.
11. Install new pin caliper boots.
12. Place caliper slide grease into the pin sleeve boots.
13. Install caliper slide pin into the rubber boots.
14. Clean any excess grease off of caliper.
15. Install inner and outer brake pads.
NOTE
THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL
BACKING PLATE.
16. Install brake caliper as per WSM, Section 206-04.
17. Repeat steps 2-16 on the other side.
18. Install the rear tires as per the WSM, Section 204-04.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4739
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092213A 2007-2010 Explorer, 0.8 Hr.
Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2200 07
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Testing and Inspection > Brake Calipers
Brake Caliper: Testing and Inspection Brake Calipers
Brake System Inspection
Brake Calipers
1. Inspect the brake calipers for leaks, damage to seals and piston corrosion or binding.
- If the brake caliper is leaking or otherwise damaged, install a new brake caliper.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Testing and Inspection > Brake Calipers > Page 4742
Brake Caliper: Testing and Inspection Brake Caliper Guide Pins
Brake System Inspection
Brake Caliper Guide Pins
1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show
taper wear or the guide pins are difficult to move,
carry out the following steps. Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for wear,
damage and corrosion. If bore is worn or damaged, replace the damaged component.
- Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign material
from the caliper guide pin bores. Clean any remaining foreign material from the bores with brake
parts cleaner and compressed air.
- Assemble the caliper seals, boots and guide pins. Use an ample amount of the specified grease
to lubricate the bores and guide pins.
- Inspect the brake pads. For additional information, refer to Brake Pads inspection. See: Testing
and Inspection/Component Tests and General Diagnostics/Brake System Inspection/Brake Pads
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Procedures
Brake Caliper: Procedures
Component Bleeding
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
1. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was
disconnected or installed new.
Remove the 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 at least 2 times 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.
4. Remove the rubber hose and tighten the bleeder screw to specifications. For additional
information, refer to Specifications.
- Install the bleeder screw cap.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Procedures > Page 4745
Brake Caliper: Removal and Replacement
Brake Caliper
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. For additional information, consult the product Material
Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious
personal injury.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface 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.
- Cap the fluid ports.
3. NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Procedures > Page 4746
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.
Brake Caliper Anchor Plate
Brake Caliper Anchor Plate
Removal and Installation
1. Remove the brake pads. For additional information, refer to Brake Pads See: Brake Pad/Service
and Repair/Front Disc Brake.
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.
Rear Disc Brake
Brake Caliper
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Procedures > Page 4747
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. For additional information, consult the product Material
Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious
personal injury.
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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Procedures > Page 4748
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 (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise
Over Bumps
Brake Pad: Customer Interest Brakes - Rear Brake Rattling Noise Over Bumps
TSB 09-22-13
11/16/09
REAR BRAKE RATTLE OVER BUMPS
FORD: 2007-2010 Explorer Sport Trac, Explorer
MERCURY: 2007-2010 Mountaineer
This article supersedes TSB 7-24-6 to update the vehicle model years covered.
ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a
rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do
not incorporate an anti-rattle clip.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
To repair the rattle noise perform the following:
1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04.
2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section
206-04.
3. Support the caliper to prevent damage to the brake line. (Figure 1)
4. Remove the outer and inner brake pad and discard pads.
5. Remove the brake pad slippers from the caliper rails and discard.
6. Clean the caliper rails with a wire brush.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4757
7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the
underside of the brake pad slippers. (Figure 2)
8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to
the upper caliper rail. The larger brake pad slipper is
attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3)
9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers.
10. Remove the caliper pin sleeves and rubber boots.
11. Install new pin caliper boots.
12. Place caliper slide grease into the pin sleeve boots.
13. Install caliper slide pin into the rubber boots.
14. Clean any excess grease off of caliper.
15. Install inner and outer brake pads.
NOTE
THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL
BACKING PLATE.
16. Install brake caliper as per WSM, Section 206-04.
17. Repeat steps 2-16 on the other side.
18. Install the rear tires as per the WSM, Section 204-04.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4758
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092213A 2007-2010 Explorer, 0.8 Hr.
Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2200 07
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake
Rattling Noise Over Bumps
Brake Pad: All Technical Service Bulletins Brakes - Rear Brake Rattling Noise Over Bumps
TSB 09-22-13
11/16/09
REAR BRAKE RATTLE OVER BUMPS
FORD: 2007-2010 Explorer Sport Trac, Explorer
MERCURY: 2007-2010 Mountaineer
This article supersedes TSB 7-24-6 to update the vehicle model years covered.
ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a
rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do
not incorporate an anti-rattle clip.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
To repair the rattle noise perform the following:
1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04.
2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section
206-04.
3. Support the caliper to prevent damage to the brake line. (Figure 1)
4. Remove the outer and inner brake pad and discard pads.
5. Remove the brake pad slippers from the caliper rails and discard.
6. Clean the caliper rails with a wire brush.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4764
7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the
underside of the brake pad slippers. (Figure 2)
8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to
the upper caliper rail. The larger brake pad slipper is
attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3)
9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers.
10. Remove the caliper pin sleeves and rubber boots.
11. Install new pin caliper boots.
12. Place caliper slide grease into the pin sleeve boots.
13. Install caliper slide pin into the rubber boots.
14. Clean any excess grease off of caliper.
15. Install inner and outer brake pads.
NOTE
THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL
BACKING PLATE.
16. Install brake caliper as per WSM, Section 206-04.
17. Repeat steps 2-16 on the other side.
18. Install the rear tires as per the WSM, Section 204-04.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4765
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092213A 2007-2010 Explorer, 0.8 Hr.
Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2200 07
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Page 4766
Brake Pad: Specifications
Brake pad minimum thickness..............................................................................................................
........................................................3.0 mm (0.118 in)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Page 4767
Brake Pad: Testing and Inspection
Brake System Inspection
Brake Pads
NOTE: It is not required to install new brake pads when the brake discs are machined.
1. Inspect the brake pad friction material for contamination.
- If the friction material shows evidence of contamination, install new brake pads.
2. Inspect and measure the thickness of the brake pad friction material. For additional information,
refer to Specifications.
- Minor surface cracks do not require pad replacement, however, if there are missing chunks or
cracks in the lining through to the backing plate, install new brake pads.
- If the thickness of the friction material is less than the specified thickness, install new brake pads.
- If the friction material shows taper wear that is not within specifications, install new brake pads
and verify the caliper guide pins are functioning correctly. For additional information, refer to Brake
Caliper Guide Pins inspection. See: Testing and Inspection/Component Tests and General
Diagnostics/Brake System Inspection/Brake Caliper Guide Pins
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front Disc Brake
Brake Pad: Service and Repair Front Disc Brake
Brake Pads
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface 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 one-half full.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front Disc Brake > Page 4770
2. Remove the wheel and tire.
3. NOTICE: Do not pry in the brake caliper sight hole to retract the pistons as this can damage the
pistons and boots.
NOTICE: 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. Remove the brake pads and clips.
- Discard the clips.
Installation
1. 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. NOTICE: 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.
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 specified brake fluid.
5. Install the wheel and tire.
- Apply brakes several times to verify correct brake operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front Disc Brake > Page 4771
Brake Pad: Service and Repair Rear Disc Brake
Brake Pads
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
1. Check the brake fluid level in the brake master cylinder reservoir.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front Disc Brake > Page 4772
- If required, remove the fluid until the brake master cylinder reservoir is half full.
2. Remove the wheel and tire.
3. NOTICE: Do not pry in the caliper sight hole to retract the pistons, as this can damage the
pistons and boots.
NOTICE: 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. Remove the 2 brake pads.
- Discard the brake pad clips.
Installation
1. Apply a thin bead of the specified sealant to the center of the inside of the brake pad clips.
2. Install the brake pad clips and brake pads.
3. NOTICE: 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.
4. Position the brake caliper and install the 2 brake caliper guide pin bolts.
- Tighten to 32 Nm (24 lb-ft).
5. Fill the brake master cylinder reservoir with clean, specified brake fluid.
6. Install the wheel and tire.
- Apply brakes several times to verify correct brake operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications > Front Brake Rotor/Disc
Brake Rotor/Disc: Specifications Front Brake Rotor/Disc
Front Brake disc minimum thickness....................................................................................................
......................................................28.5 mm (1.122 in)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications > Front Brake Rotor/Disc > Page 4777
Brake Rotor/Disc: Specifications Rear Brake Rotor/Disc
Rear Brake disc minimum thickness....................................................................................................
.......................................................11.0 mm (0.433 in)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications > Page 4778
Brake Rotor/Disc: Testing and Inspection
Brake System Inspection
Brake Discs
NOTICE: Using an impact tool without a torque socket will lead to unevenly tightened wheel nuts.
This causes brake disc on-vehicle lateral runout and brake roughness.
1. Inspect the brake discs and measure the brake disc thickness in a minimum of 4 places around
the circumference of the brake disc. Record the
measurements, refer to Specifications. If the brake disc is cracked or otherwise damaged, install a new brake disc.
- If any measurement is below the minimum thickness specification, install a new brake disc.
- If the diagnosis has revealed vibration in the steering wheel, seat or pedal while braking that
varies with vehicle speed, machine the brake disc. Heavily scored brake discs, similar to that
caused by pads worn down to the backing plate, should also be machined. In order to machine,
discs must be above the minimum thickness specification. For additional information, refer to
Specifications and Brake Disc Machining See: Service and Repair/Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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. Use an on-vehicle brake lathe only.
Read the entire operating manual and/or view the video shipped with the lathe before installing,
operating or repairing the lathe.
NOTE: An on-vehicle brake lathe with an automatic runout adjustment feature is preferred.
However, if the lathe is not self adjusting, the lathe oscillation must be adjusted using a dial
indicator. The total indicated runout target is 0.000 mm (0.000 in). The maximum indicated runout
should be no more than 0.050 mm (0.002 in). If the runout adjustment (automatic or manual) is
carried out correctly prior to machining, then the final brake disc runout will be within specification
and a runout measurement is not necessary after machining.
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
specification.
1. Remove the wheel and tire.
2. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose may
occur.
Remove the bolts and position the brake caliper or brake caliper and anchor plate assembly aside,
as required.
- Support the brake caliper using mechanic's wire.
3. Install the hub adapter using:
- four wheel nuts on a 4-stud wheel hub.
- five wheel nuts on a 5-stud wheel hub.
- six wheel nuts on a 6-stud wheel hub.
- four wheel nuts on a 7- or 8-stud wheel hub.
- five wheel nuts on a 10-stud wheel hub.
4. Install the cutting lathe.
5. If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. The total
indicated runout target is 0.000 mm (0.000 in). The
maximum indicated runout should be no more than 0.050 mm (0.002 in).
6. Center the cutting head, adjust the cutting bits and install the chip deflector/silencer.
7. NOTE: The depth of the cut should be between 0.10 and 0.40 mm (0.004 and 0.015 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.
8. Remove the lathe and the silencer.
9. Remove the wheel nuts and hub adapter.
10. Remove the metal shavings.
11. NOTE: It is not required to install new brake pads if friction material is within specifications. For
additional information, refer to Specifications.
Position the brake caliper or brake caliper and anchor plate assembly.
- Install the bolts.
- For fastener torque specifications, refer to Disc Brake System. See: Specifications
12. Install the wheel and tire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Procedures > Page 4781
Brake Rotor/Disc: Removal and Replacement
Brake Disc
Brake Disc
Removal
1. NOTICE: 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.
2. NOTE: If the brake disc cannot be removed easily, apply specified 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 specified parts cleaner to clean the front brake disc and hub surfaces.
2. Apply a thin coat of specified 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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Procedures > Page 4782
Brake Disc Shield
Brake Disc Shield
Removal and Installation
1. Remove the brake disc. For additional information, refer to Brake Disc See: Front Disc
Brake/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.
Brake Disc
Brake Disc
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Procedures > Page 4783
Removal
1. Remove the wheel and tire.
2. NOTICE: Do not pry in the caliper sight hole to retract the pistons, as this can damage the
pistons and boots.
NOTICE: 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 specified penetrating and 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 specified 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.
Brake Disc Shield
Brake Disc Shield
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Procedures > Page 4784
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 (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Component Bleeding
Brake Bleeding: Service and Repair Component Bleeding
Master Cylinder
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
NOTE: When a new brake master cylinder is installed, or the system is 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.
3. Fill the brake master cylinder reservoir with clean, specified brake fluid.
4. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air
bubbles.
5. Remove the short brake tubes and install the brake outlet tubes.
6. 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,
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Component Bleeding > Page 4790
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 brake tube fittings to specifications. For additional information, refer to
Specifications.
7. Bleed the brake system, refer to Brake System Bleeding See: Brake System Bleeding.
Brake Caliper
Component Bleeding
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
1. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was
disconnected or installed new.
Remove the 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 at least 2 times 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.
4. Remove the rubber hose and tighten the bleeder screw to specifications. For additional
information, refer to Specifications.
- Install the bleeder screw cap.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Component Bleeding > Page 4791
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Component Bleeding > Page 4792
Brake Bleeding: Service and Repair Brake System Bleeding
Brake System Bleeding
Pressure
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any
components upstream of the HCU are installed new.
NOTE: Pressure bleeding the brake system is preferred to manual bleeding.
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: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the equipment 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: Make sure the bleeder tank contains enough clean, specified brake fluid to complete the
bleeding operation.
Remove the RH rear 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Component Bleeding > Page 4793
4. Open the valve on the bleeder tank.
- Set pressure to 207-345 kPa (30-50 psi).
5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then
tighten the RH rear bleeder screw and remove the
rubber hose. Tighten to specifications. For additional information, refer to Specifications.
- Install the bleeder screw cap.
6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front
bleeder screw ending with the LH front bleeder
screw.
7. Release the bleeder tank pressure and close the bleeder tank valve. Remove the tank hose from
the adapter and remove the adapter from the brake
fluid reservoir.
Manual
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any
components upstream of the HCU are installed new.
NOTE: Pressure bleeding the brake system is preferred to manual bleeding.
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. Remove the bleeder screw cap and place a box-end wrench on the RH rear bleeder screw.
Attach a rubber drain hose to the RH rear bleeder screw
and submerge the free end of the hose in a container partially filled with clean, specified brake
fluid.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Component Bleeding > Page 4794
3. Have an assistant pump the brake pedal at least 3 times and then hold firm pressure on the
brake pedal.
4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the
RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
5. Remove the rubber hose and tighten the bleeder screw to specifications. For additional
information, refer to Specifications.
- Install the bleeder screw cap.
6. Repeat Steps 2 through 5 for the LH rear, RH front and LH front bleeder screws in this order.
Hydraulic Control Unit (HCU)
NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any
components upstream of the HCU are installed new.
NOTE: Pressure bleeding the brake system is preferred to manual bleeding.
1. Follow the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system.
2. Connect the scan tool and follow the ABS Service Bleed instructions.
3. Repeat the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear
Brake Rattling Noise Over Bumps
Brake Caliper: Customer Interest Brakes - Rear Brake Rattling Noise Over Bumps
TSB 09-22-13
11/16/09
REAR BRAKE RATTLE OVER BUMPS
FORD: 2007-2010 Explorer Sport Trac, Explorer
MERCURY: 2007-2010 Mountaineer
This article supersedes TSB 7-24-6 to update the vehicle model years covered.
ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a
rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do
not incorporate an anti-rattle clip.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
To repair the rattle noise perform the following:
1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04.
2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section
206-04.
3. Support the caliper to prevent damage to the brake line. (Figure 1)
4. Remove the outer and inner brake pad and discard pads.
5. Remove the brake pad slippers from the caliper rails and discard.
6. Clean the caliper rails with a wire brush.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4803
7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the
underside of the brake pad slippers. (Figure 2)
8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to
the upper caliper rail. The larger brake pad slipper is
attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3)
9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers.
10. Remove the caliper pin sleeves and rubber boots.
11. Install new pin caliper boots.
12. Place caliper slide grease into the pin sleeve boots.
13. Install caliper slide pin into the rubber boots.
14. Clean any excess grease off of caliper.
15. Install inner and outer brake pads.
NOTE
THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL
BACKING PLATE.
16. Install brake caliper as per WSM, Section 206-04.
17. Repeat steps 2-16 on the other side.
18. Install the rear tires as per the WSM, Section 204-04.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4804
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092213A 2007-2010 Explorer, 0.8 Hr.
Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2200 07
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 >
Brakes - Rear Brake Rattling Noise Over Bumps
Brake Caliper: All Technical Service Bulletins Brakes - Rear Brake Rattling Noise Over Bumps
TSB 09-22-13
11/16/09
REAR BRAKE RATTLE OVER BUMPS
FORD: 2007-2010 Explorer Sport Trac, Explorer
MERCURY: 2007-2010 Mountaineer
This article supersedes TSB 7-24-6 to update the vehicle model years covered.
ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a
rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do
not incorporate an anti-rattle clip.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
To repair the rattle noise perform the following:
1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04.
2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section
206-04.
3. Support the caliper to prevent damage to the brake line. (Figure 1)
4. Remove the outer and inner brake pad and discard pads.
5. Remove the brake pad slippers from the caliper rails and discard.
6. Clean the caliper rails with a wire brush.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4810
7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the
underside of the brake pad slippers. (Figure 2)
8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to
the upper caliper rail. The larger brake pad slipper is
attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3)
9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers.
10. Remove the caliper pin sleeves and rubber boots.
11. Install new pin caliper boots.
12. Place caliper slide grease into the pin sleeve boots.
13. Install caliper slide pin into the rubber boots.
14. Clean any excess grease off of caliper.
15. Install inner and outer brake pads.
NOTE
THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL
BACKING PLATE.
16. Install brake caliper as per WSM, Section 206-04.
17. Repeat steps 2-16 on the other side.
18. Install the rear tires as per the WSM, Section 204-04.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4811
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092213A 2007-2010 Explorer, 0.8 Hr.
Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2200 07
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Testing and Inspection > Brake Calipers
Brake Caliper: Testing and Inspection Brake Calipers
Brake System Inspection
Brake Calipers
1. Inspect the brake calipers for leaks, damage to seals and piston corrosion or binding.
- If the brake caliper is leaking or otherwise damaged, install a new brake caliper.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Testing and Inspection > Brake Calipers > Page 4814
Brake Caliper: Testing and Inspection Brake Caliper Guide Pins
Brake System Inspection
Brake Caliper Guide Pins
1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show
taper wear or the guide pins are difficult to move,
carry out the following steps. Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for wear,
damage and corrosion. If bore is worn or damaged, replace the damaged component.
- Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign material
from the caliper guide pin bores. Clean any remaining foreign material from the bores with brake
parts cleaner and compressed air.
- Assemble the caliper seals, boots and guide pins. Use an ample amount of the specified grease
to lubricate the bores and guide pins.
- Inspect the brake pads. For additional information, refer to Brake Pads inspection. See: Testing
and Inspection/Component Tests and General Diagnostics/Brake System Inspection/Brake Pads
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Procedures
Brake Caliper: Procedures
Component Bleeding
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
1. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was
disconnected or installed new.
Remove the 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 at least 2 times 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.
4. Remove the rubber hose and tighten the bleeder screw to specifications. For additional
information, refer to Specifications.
- Install the bleeder screw cap.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Procedures > Page 4817
Brake Caliper: Removal and Replacement
Brake Caliper
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. For additional information, consult the product Material
Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious
personal injury.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface 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.
- Cap the fluid ports.
3. NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Procedures > Page 4818
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.
Brake Caliper Anchor Plate
Brake Caliper Anchor Plate
Removal and Installation
1. Remove the brake pads. For additional information, refer to Brake Pads See: Disc Brake
System/Brake Pad/Service and Repair/Front Disc Brake.
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.
Rear Disc Brake
Brake Caliper
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Procedures > Page 4819
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. For additional information, consult the product Material
Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious
personal injury.
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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Procedures > Page 4820
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 (V6-4.0L (2009))
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-C Ford Specification
......................................................................................................................................................
WSS-M6C62-A or WSS-M6C65-A1.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations
Brake Fluid Level Sensor/Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations > Page 4827
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations > Page 4828
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Testing and Inspection
Brake Hose/Line: Testing and Inspection
Brake System Inspection
Brake Flexible Hoses and Tubes
NOTICE: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which may result
in brake tube failure.
NOTE: Double-wall steel tubing is used throughout the brake hydraulic system. All brake tube
fittings must be correctly double flared to provide strong, leakproof connections. When bending
tubing to fit the underbody or rear axle contours, be careful not to kink or crack the tube.
1. Inspect brake tubes for corrosion, cracks, leaks or any other signs of damage.
- If a section of the brake tube is damaged, the entire section must be installed with a new tube of
the same type, size, shape and length.
- When installing the hydraulic brake tubing, hoses or connectors, tighten all connections to
specifications. After installation, bleed the brake system. For additional information, refer to Brake
System Bleeding See: Brake Bleeding/Service and Repair/Brake System Bleeding.
2. Inspect the brake flexible hoses for cracks, leaks and swelling during brake application or any
other signs of damage.
- Install a new brake flexible hose if the hose shows signs of softening, cracking or other damage.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Front Disc Brake
Brake Hose/Line: Service and Repair Front Disc Brake
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. For additional information, consult the product Material
Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious
personal injury.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface 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.
- To install, tighten to 18 Nm (159 lb-in).
3. Remove the brake flexible hose retaining clip and the brake flexible hose.
4. To install, reverse the removal procedure.
- Bleed the brake caliper.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Front Disc Brake > Page 4834
Brake Hose/Line: Service and Repair Rear Disc Brake
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. For additional information, consult the product Material
Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious
personal injury.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface 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.
- To install, tighten to 18 Nm (159 lb-in).
4. Remove the brake flexible hose bracket bolt and the brake hose.
- To install, tighten to 20 Nm (177 lb-in).
5. To install, reverse the removal procedure.
- Bleed the brake caliper.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Service and Repair
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Hydraulic Control Unit (HCU)
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Service and Repair > Page 4838
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. For additional information, consult the product Material
Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious
personal injury.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
1. With the vehicle in NEUTRAL, position it on a hoist.
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.
Disconnect the master cylinder primary and secondary brake tube-to-Hydraulic Control Unit (HCU)
fittings and position both brake tubes aside.
- To install, tighten to 25 Nm (18 lb-ft).
5. NOTE: The brake tubes must be installed in the same location as removed.
Disconnect the 4 brake tube-to-HCU extension tube fittings.
- To install, tighten to 18 Nm (159 lb-in).
6. Remove the 3 HCU bracket-to-frame nuts and the HCU assembly.
- To install, tighten the nuts to 23 Nm (17 lb-ft).
7. NOTE: The brake tubes must be installed in the same location as removed.
Disconnect the 4 HCU extension tube-to-HCU fittings.
- To install, tighten to 18 Nm (159 lb-in).
8. Remove the 2 HCU bracket-to-HCU extension tube retainer nuts and the extension tube retainer
assembly.
- To install, tighten the nuts to 9 Nm (80 lb-in).
9. Remove the HCU bracket-to-HCU bolt and the HCU bracket.
- To install, tighten the bolts to 9 Nm (80 lb-in).
10. To install, reverse the removal procedure.
- Bleed the brake system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Component Tests
Brake Master Cylinder - Bypass Condition
1. Inspect the master cylinder. For additional information, refer to Brake System Inspection See:
Testing and Inspection/Component Tests and
General Diagnostics/Brake System Inspection.
2. Disconnect the brake tubes from the master cylinder.
3. Plug the outlet ports of the master cylinder.
4. NOTE: Make sure that the outlet port plugs do not show signs of leakage.
Lightly apply the brakes and hold for 10 seconds. Release the brakes and then reapply with heavy
force. 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 (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 4843
Brake Master Cylinder: Testing and Inspection Brake Master Cylinder - Compensator Port
Component Tests
Brake Master Cylinder - Compensator Port
1. Inspect the master cylinder. For additional information, refer to Brake System Inspection See:
Testing and Inspection/Component Tests and
General Diagnostics/Brake System Inspection.
2. With the vehicle in NEUTRAL, position it on a hoist. Refer to Maintenance/Service and Repair.
3. Apply and release the brakes.
4. With the brakes released, attempt to rotate each wheel and check for any brake drag.
- If an excessive amount of brake drag exists at multiple wheels, continue to Step 4.
- 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.
5. Check the brake stoplamp switch and the brake pedal free play to verify that the brake pedal is
not partially applied.
6. Loosen the brake master cylinder nuts and position the brake master cylinder away from the
brake booster.
7. 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 (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 4844
Brake Master Cylinder: Testing and Inspection Brake System Inspection
Brake Pads
Brake System Inspection
Brake Pads
NOTE: It is not required to install new brake pads when the brake discs are machined.
1. Inspect the brake pad friction material for contamination.
- If the friction material shows evidence of contamination, install new brake pads.
2. Inspect and measure the thickness of the brake pad friction material. For additional information,
refer to Specifications.
- Minor surface cracks do not require pad replacement, however, if there are missing chunks or
cracks in the lining through to the backing plate, install new brake pads.
- If the thickness of the friction material is less than the specified thickness, install new brake pads.
- If the friction material shows taper wear that is not within specifications, install new brake pads
and verify the caliper guide pins are functioning correctly. For additional information, refer to Brake
Caliper Guide Pins inspection. See: Testing and Inspection/Component Tests and General
Diagnostics/Brake System Inspection/Brake Caliper Guide Pins
Brake Discs
Brake System Inspection
Brake Discs
NOTICE: Using an impact tool without a torque socket will lead to unevenly tightened wheel nuts.
This causes brake disc on-vehicle lateral runout and brake roughness.
1. Inspect the brake discs and measure the brake disc thickness in a minimum of 4 places around
the circumference of the brake disc. Record the
measurements, refer to Specifications. If the brake disc is cracked or otherwise damaged, install a new brake disc.
- If any measurement is below the minimum thickness specification, install a new brake disc.
- If the diagnosis has revealed vibration in the steering wheel, seat or pedal while braking that
varies with vehicle speed, machine the brake disc. Heavily scored brake discs, similar to that
caused by pads worn down to the backing plate, should also be machined. In order to machine,
discs must be above the minimum thickness specification. For additional information, refer to
Specifications and Brake Disc Machining See: Disc Brake System/Brake Rotor/Disc/Service and
Repair/Procedures.
Brake Calipers
Brake System Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 4845
Brake Calipers
1. Inspect the brake calipers for leaks, damage to seals and piston corrosion or binding.
- If the brake caliper is leaking or otherwise damaged, install a new brake caliper.
Brake Caliper Guide Pins
Brake System Inspection
Brake Caliper Guide Pins
1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show
taper wear or the guide pins are difficult to move,
carry out the following steps. Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for wear,
damage and corrosion. If bore is worn or damaged, replace the damaged component.
- Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign material
from the caliper guide pin bores. Clean any remaining foreign material from the bores with brake
parts cleaner and compressed air.
- Assemble the caliper seals, boots and guide pins. Use an ample amount of the specified grease
to lubricate the bores and guide pins.
- Inspect the brake pads. For additional information, refer to Brake Pads inspection. See: Testing
and Inspection/Component Tests and General Diagnostics/Brake System Inspection/Brake Pads
Brake Flexible Hoses and Tubes
Brake System Inspection
Brake Flexible Hoses and Tubes
NOTICE: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which may result
in brake tube failure.
NOTE: Double-wall steel tubing is used throughout the brake hydraulic system. All brake tube
fittings must be correctly double flared to provide strong, leakproof connections. When bending
tubing to fit the underbody or rear axle contours, be careful not to kink or crack the tube.
1. Inspect brake tubes for corrosion, cracks, leaks or any other signs of damage.
- If a section of the brake tube is damaged, the entire section must be installed with a new tube of
the same type, size, shape and length.
- When installing the hydraulic brake tubing, hoses or connectors, tighten all connections to
specifications. After installation, bleed the brake system. For additional information, refer to Brake
System Bleeding See: Brake Bleeding/Service and Repair/Brake System Bleeding.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 4846
2. Inspect the brake flexible hoses for cracks, leaks and swelling during brake application or any
other signs of damage.
- Install a new brake flexible hose if the hose shows signs of softening, cracking or other damage.
Brake Master Cylinder
Brake System Inspection
Brake Master Cylinder
NOTE: During normal operation of the brake master cylinder, the fluid level in the brake master
cylinder reservoir will fall during brake application and rise during release. The returning brake fluid
creates a slight turbulance in the 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. The net fluid level (such as after brake application and release) will
remain unchanged. Fluid level will decrease with pad wear.
NOTE: A trace of brake fluid will exist on the booster shell below the master cylinder mounting
flange. This results from the normal lubricating action of the master cylinder bore and seal.
1. Inspect the brake master cylinder for fluid leaks.
- Install a new master cylinder or brake fluid reservoir if signs of excessive leaking are present. For
additional information, refer to Brake Master Cylinder.
- To check for correct brake master cylinder operation, refer to Component Tests See: Testing and
Inspection/Component Tests and General Diagnostics.
Brake Booster
Brake System Inspection
Brake Booster
1. Inspect the brake booster for excessive corrosion or damage. Inspect the vacuum hoses for
leaks and kinks.
- Install a new brake booster if signs of excessive corrosion or damage is found. For additional
information, refer to Power Brake Assist.
- Repair or replace vacuum hoses as necessary.
- To check for correct brake booster operation, refer to Component Tests See: Testing and
Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 4847
Brake Master Cylinder: Testing and Inspection Brake Booster
Component Tests
Brake Booster
1. Inspect the brake booster. For additional information, refer to Brake System Inspection See:
Testing and Inspection/Component Tests and General
Diagnostics/Brake System Inspection.
2. Disconnect the check valve from the brake booster and connect a suitable vacuum/pressure
tester to the booster side of the check valve.
3. Apply the parking brake, start the engine and place the transmission in NEUTRAL.
- Allow the engine to reach normal operating temperature.
4. NOTE: Subtract approximately 4.0193 kPa (1 in-Hg) from the specified reading for every 304.8
m (1,000 ft) of elevation above sea level.
Verify that vacuum is available at the check valve with engine running at normal idle speed.
- The vacuum gauge should read between 51-74 kPa (15-22 in-Hg).
- If specified vacuum is available, stop the engine, connect the check valve and continue with Step
5.
- If specified vacuum is not available, continue with Step 4.
5. Disconnect the check valve from the vacuum hose and verify that the specified vacuum is
available at the hose with the engine at idle speed and
the transmission in NEUTRAL. If specified vacuum is available, stop the engine, install a new check valve and continue with Step
5.
- If specified vacuum is not available, stop the engine, connect the vacuum hose to the check valve
and refer to Engine to diagnose the no/low vacuum condition. See: Engine, Cooling and
Exhaust/Engine/Testing and Inspection
6. Apply the brake pedal several times to exhaust all vacuum from the system.
7. 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.
8. Operate the engine a minimum of 20 seconds at idle. Stop the engine and let the vehicle stand
for 10 minutes, then apply the brake pedal. 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 condition still exists, install a new brake booster.
- If the brake pedal feels the same as noted with the engine operating, the check valve is
functioning properly.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Procedures
Brake Master Cylinder: Procedures
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. 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
NOTE: When a new brake master cylinder is installed, or the system is 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.
3. Fill the brake master cylinder reservoir with clean, specified brake fluid.
4. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air
bubbles.
5. Remove the short brake tubes and install the brake outlet tubes.
6. 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Procedures > Page 4850
4. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the
front brake tube.
5. Tighten the brake tube fittings to specifications. For additional information, refer to
Specifications.
7. Bleed the brake system, refer to Brake System Bleeding See: Brake Bleeding/Service and
Repair/Brake System Bleeding.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Procedures > Page 4851
Brake Master Cylinder: Removal and Replacement
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. For additional information, consult the product Material
Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious
personal injury.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with
water.
1. With the engine off, press the brake pedal several times to deplete the brake booster vacuum.
2. Disconnect the brake fluid level warning switch electrical connector.
3. Disconnect the 2 brake tube fittings from the brake master cylinder.
- To install, tighten to 18 Nm (159 lb-in).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Procedures > Page 4852
- Bleed the brake system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
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 (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 4858
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. For additional information, refer to Parking Brake
Cable Tension Release See: Procedures.
2. With the vehicle in NEUTRAL, position it on a hoist.
3. Remove the wire form bolt.
- To install, tighten to 23 Nm (17 lb-ft).
4. Remove the bracket bolt.
- 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 4859
Parking Brake Cable - Rear, RH
Removal and Installation
1. Release the parking brake cable tension. For additional information, refer to Parking Brake
Cable Tension Release See: Procedures.
2. With the vehicle in NEUTRAL position it on a hoist.
3. Remove the 2 wire form bolts.
- To install, tighten to 15 Nm (133 lb-in).
4. Remove the 2 parking brake cable bracket-to-crossmember bolts.
- To install, tighten to 15 Nm (133 lb-in).
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 (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 4860
Removal and Installation
1. Remove the parking brake control. For additional information, refer to Parking Brake Control
See: Parking Brake Control/Service and Repair.
2. 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.
3. 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 (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 4861
Removal and Installation
1. Release the tension on the parking brake cable. For additional information, refer to Parking
Brake Cable Tension Release See: Procedures.
2. With the vehicle in NEUTRAL, position it on a hoist.
3. Disconnect the intermediate parking brake cable from the front cable at the cable connector clip.
4. Disconnect the LH and RH rear parking brake cables from the intermediate parking brake cable
at the equalizer.
5. Remove the intermediate parking brake cable.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
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. For additional information, refer to Parking
Brake Cable Tension Release See: Parking Brake
Cable/Service and Repair/Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Service and Repair > Page 4865
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 (177 lb-in).
10. Position the carpet aside and position the cable conduit grommet up through the floor.
11. Remove the parking brake control and cable assembly.
12. To install, reverse the removal procedure.
- Test the parking brake system for correct operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications
Parking Brake Shoe: Specifications
Minimum Thickness..............................................................................................................................
.....................................................0.54 mm (0.021 in)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications > Page 4869
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 Brake Adjusting Gauge, measure the inside diameter of the drum portion of the rear
brake disc and set the locking screw.
- Record the measurement.
4. Place the Brake Adjusting Gauge 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 (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications > Page 4870
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 See: Parking Brake Cable/Service and Repair/Procedures.
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
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications > Page 4871
5. Adjust the parking brake shoe. For additional information, refer to Parking Brake Shoe
Adjustment See: Adjustments.
6. Reload the tension on the parking brake cable. For additional information, refer to Parking Brake
Cable Tension Release See: Parking Brake
Cable/Service and Repair/Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Locations
Parking Brake Warning Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Locations > Page 4875
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Locations > Page 4876
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor >
Component Information > Locations
Brake Booster Vacuum Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor >
Component Information > Locations > Page 4881
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor >
Component Information > Locations > Page 4882
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications
Vacuum Brake Booster: Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 4886
Vacuum Brake Booster: Description and Operation
Brake Booster
The power brake actuation system consists of the following components:
- Brake booster
- Brake booster check valve
- Brake booster vacuum supply hose
The brake booster uses engine vacuum from the intake manifold to create a partial vacuum inside
the vacuum booster on both sides of the diaphragm. When the brake pedal is pressed, the booster
rod opens a valve, allowing air to enter the booster on one side of the diaphragm while sealing off
the opposite side. This increases pressure on that side of the diaphragm so that it helps push the
rod, which in turn pushes the piston in the master cylinder. As the brake pedal is released, the
valve seals off the outside air supply while opening the vacuum valve. This restores vacuum to
both sides of the diaphragm, allowing everything to return to its original position.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Testing and Inspection > Brake Booster
Vacuum Brake Booster: Testing and Inspection Brake Booster
Component Tests
Brake Booster
1. Inspect the brake booster. For additional information, refer to Brake System Inspection See:
Testing and Inspection/Component Tests and General
Diagnostics/Brake System Inspection.
2. Disconnect the check valve from the brake booster and connect a suitable vacuum/pressure
tester to the booster side of the check valve.
3. Apply the parking brake, start the engine and place the transmission in NEUTRAL.
- Allow the engine to reach normal operating temperature.
4. NOTE: Subtract approximately 4.0193 kPa (1 in-Hg) from the specified reading for every 304.8
m (1,000 ft) of elevation above sea level.
Verify that vacuum is available at the check valve with engine running at normal idle speed.
- The vacuum gauge should read between 51-74 kPa (15-22 in-Hg).
- If specified vacuum is available, stop the engine, connect the check valve and continue with Step
5.
- If specified vacuum is not available, continue with Step 4.
5. Disconnect the check valve from the vacuum hose and verify that the specified vacuum is
available at the hose with the engine at idle speed and
the transmission in NEUTRAL. If specified vacuum is available, stop the engine, install a new check valve and continue with Step
5.
- If specified vacuum is not available, stop the engine, connect the vacuum hose to the check valve
and refer to Engine to diagnose the no/low vacuum condition. See: Engine, Cooling and
Exhaust/Engine/Testing and Inspection
6. Apply the brake pedal several times to exhaust all vacuum from the system.
7. 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.
8. Operate the engine a minimum of 20 seconds at idle. Stop the engine and let the vehicle stand
for 10 minutes, then apply the brake pedal. 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 condition still exists, install a new brake booster.
- If the brake pedal feels the same as noted with the engine operating, the check valve is
functioning properly.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Testing and Inspection > Brake Booster > Page 4889
Vacuum Brake Booster: Testing and Inspection Brake System Inspection - Brake Booster
Brake System Inspection
Brake Booster
1. Inspect the brake booster for excessive corrosion or damage. Inspect the vacuum hoses for
leaks and kinks.
- Install a new brake booster if signs of excessive corrosion or damage is found. For additional
information, refer to Power Brake Assist.
- Repair or replace vacuum hoses as necessary.
- To check for correct brake booster operation, refer to Component Tests See: Testing and
Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Testing and Inspection > Page 4890
Vacuum Brake Booster: Service and Repair
Brake Booster
Removal and Installation
1. NOTICE: 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. NOTICE: Do not service the brake pedal or brake booster without first removing the stoplamp
switch. This switch must be removed with
the brake pedal in the at-rest position. The switch plunger 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.
4. 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.
Disconnect the brake booster solenoid electrical connector.
5. 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.
6. Disconnect the brake booster rod from the brake pedal and position aside.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Testing and Inspection > Page 4891
7. Remove and discard the 4 brake booster nuts and the booster.
- To install, tighten the new nuts to 22 Nm (16 lb-ft).
8. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp
switch. This switch must be installed with
the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position.
Installing this switch with the brake pedal in any other position will result in incorrect adjustment
and may damage the switch.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component
Information > Locations > Page 4896
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 4901
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 4902
Electronic Brake Control Module: Diagrams
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 4903
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 4904
Electronic Brake Control Module: Service and Repair
Anti-Lock Brake System (ABS) Module
Removal and Installation
NOTICE: 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. See: Powertrain
Management/Computers and Control Systems/Information Bus/Testing and
Inspection/Programming and Relearning
1. Remove the Hydraulic Control Unit (HCU). For additional information, refer to Hydraulic Control
Unit (HCU) See: Antilock Brakes / Traction
Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair.
2. Remove the 4 screws and the ABS module.
- To install, tighten to 2 Nm (18 lb-in).
3. NOTICE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake
Control Module > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake
Control Module > Component Information > Locations > Page 4908
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS
Sensor Block > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS
Sensor Block > Component Information > Locations > Page 4913
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Service and Repair
Acceleration/Deceleration Sensor: Service and Repair
Stability Control Sensor Cluster
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 4917
- To install, tighten to 7 Nm (62 lb-in).
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Page 4921
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Page 4922
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 4926
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 4927
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Locations > Page 4931
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Locations > Page 4932
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 screws and the steering wheel rotation sensor.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations > Page 4939
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations > Page 4940
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.
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 (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4945
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4946
Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4947
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4948
Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Rear
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4949
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4950
Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Rear
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4951
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4954
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4955
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4956
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
- To install, tighten to 8 Nm (71 lb-in).
4. Remove the wheel speed sensor harness pin-type retainers.
5. Remove the wheel speed sensor bolt and the wheel speed sensor.
- To install, tighten the bolt to 17 Nm (150 lb-in).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4959
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.
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 (V6-4.0L (2009))
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 4960
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring - Rear
Wheel Speed Sensor Ring - Rear
Removal
1. Remove the rear halfshaft.
2. Using a suitable driver, remove the ABS wheel speed sensor ring.
Installation
1. Install the new ABS wheel speed sensor and the Wheel Speed Sensor Ring Installers on the
halfshaft as shown.
2. Using the Wheel Speed Sensor Ring Installers, install the ABS wheel speed sensor ring as
shown.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 4961
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Ignition Lock Cylinder - Functional
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.
NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a
new lock cylinder using the appropriate lock repair package. The lock repair package includes a
detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. With the ignition switch in the RUN position, press the locking pin with a suitable tool and remove
the ignition lock cylinder.
2. If a new lock cylinder with keys is replaced, the new Passive Anti-Theft System (PATS) keys
must be programmed.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page
4969
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Ignition Lock Cylinder - Non Functional
Removal
1. Remove the Passive Anti-Theft System (PATS) transceiver.
2. Remove the ignition lock cylinder.
- Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
- Use a 3/8-inch diameter drill bit to drill down the middle of the ignition lock key slot until the
ignition lock cylinder breaks loose.
- Remove and discard the ignition lock cylinder and drill shavings from the steering column.
3. Remove the bearing retainer.
4. Remove the steering column lock housing bearing and steering column lock gear.
Installation
1. Thoroughly clean all drill shavings from the steering column and inspect it for damage.
2. Install a new ignition lock cylinder.
- Verify the ignition lock cylinder operation.
3. Program the new PATS keys.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
Neutral Safety Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 4973
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 4974
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Starter Relay
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Starter Relay > Page 4980
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Testing and Inspection > Starter Relay
Starter Relay: Testing and Inspection Starter Relay
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Testing and Inspection > Starter Relay > Page 4983
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Testing and Inspection > Starter Relay > Page 4984
Starter Relay: Testing and Inspection Run/Start Relay
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Testing and Inspection > Starter Relay > Page 4985
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair
Battery Cable: Service and Repair
Battery Cables - 4.0L
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair
> Page 4990
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery. For additional information, refer to Battery Disconnect See: Service and
Repair/Battery Disconnect.
3. Remove the starter solenoid terminals protective cap.
4. Remove the starter solenoid wire cable terminal nut.
- To install, tighten to 6 Nm (53 lb-in).
5. Remove the starter solenoid positive cable terminal nut.
- To install, tighten to 12 Nm (106 lb-in).
6. Disconnect the starter solenoid wire cable terminal.
7. Disconnect the starter solenoid positive cable terminal.
8. Remove the nut and disconnect the starter motor ground cable terminal.
- To install, tighten to 25 Nm (18 lb-ft).
9. Disconnect the power steering pressure switch electrical connector.
10. Disconnect the A/C compressor electrical connector.
11. Disconnect the oil pressure sending unit electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair
> Page 4991
12. Remove the nut and position the battery cable engine front cover bracket aside.
- To install, tighten to 20 Nm (177 lb-in).
13. Remove the nut and position the battery cable frame bracket aside.
- To install, tighten to 9 Nm (80 lb-in).
14. Release the battery cable harness locators from the front of the engine.
15. Disconnect the 2 generator electrical connectors.
16. Position the protective cover aside, remove the nut and position the generator B+ terminal
aside.
- To install, tighten to 17 Nm (150 lb-in).
17. Release the battery cable harness locator from the generator harness guide.
18. Open the Battery Junction Box (BJB) cover and remove the 2 BJB nuts.
- To install, tighten to 9 Nm (80 lb-in).
19. Disconnect the BJB terminal.
20. Remove the nut and position the battery cable body ground terminal aside.
- To install, tighten to 9 Nm (80 lb-in).
21. Remove the 2 battery cable harness locators from the battery tray.
22. Disconnect the battery cable harness electrical connector.
23. Remove the battery cables.
24. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications
Alternator: Electrical Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications > Page 4997
Alternator: Mechanical Specifications
General Specifications
Torque Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 4998
Alternator: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 4999
Alternator: Description and Operation
Charging System
The charging system is a negative ground system consisting of:
- a generator.
- an internal voltage regulator.
- a charging system warning indicator.
- a battery.
- circuitry and cables.
- a PCM.
The generator is driven by the accessory drive belt. When the engine is started, the generator
begins to generate AC which is internally converted to DC. The DC is controlled by the voltage
regulator (located on the rear of the generator) and supplied to the battery. The PCM controls the
voltage regulation set point, working with the generator internal voltage regulator over 2 control and
communication circuits.
The generator and voltage regulator:
- supply current to the electrical system.
- charge the battery.
- adjust the generator field current to increase or decrease the generator output.
- have a PCM-controlled warning lamp.
- output is controlled by the PCM.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 5000
Alternator: Service and Repair
Generator - 4.0L SOHC
Removal and Installation
1. Disconnect the battery.
2. Rotate the Front End Accessory Drive (FEAD) belt tensioner counterclockwise and position the
FEAD belt aside.
3. Position the protective cover aside and remove and discard the generator B+ terminal nut.
- To install, tighten to 17 Nm (150 lb-in).
4. Disconnect the generator B+ terminal and the 2 electrical connectors.
5. Remove the 3 bolts and the generator.
- To install, tighten to 47 Nm (35 lb-ft).
6. If necessary, remove the nut and the generator pulley.
- To install, tighten to 109 Nm (80 lb-ft).
7. If necessary, remove the cap and nut and position the radial adapter aside.
- To install, tighten to 11 Nm (97 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 5001
8. To install, reverse the removal procedure.
- Install a new generator B+ terminal nut.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Ignition Lock Cylinder - Functional
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.
NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a
new lock cylinder using the appropriate lock repair package. The lock repair package includes a
detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. With the ignition switch in the RUN position, press the locking pin with a suitable tool and remove
the ignition lock cylinder.
2. If a new lock cylinder with keys is replaced, the new Passive Anti-Theft System (PATS) keys
must be programmed.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5008
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Ignition Lock Cylinder - Non Functional
Removal
1. Remove the Passive Anti-Theft System (PATS) transceiver.
2. Remove the ignition lock cylinder.
- Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
- Use a 3/8-inch diameter drill bit to drill down the middle of the ignition lock key slot until the
ignition lock cylinder breaks loose.
- Remove and discard the ignition lock cylinder and drill shavings from the steering column.
3. Remove the bearing retainer.
4. Remove the steering column lock housing bearing and steering column lock gear.
Installation
1. Thoroughly clean all drill shavings from the steering column and inspect it for damage.
2. Install a new ignition lock cylinder.
- Verify the ignition lock cylinder operation.
3. Program the new PATS keys.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and
Inspection > Key Programming Switch State Control
Key: Testing and Inspection Key Programming Switch State Control
Key Programming Switch State Control
NOTE: The spare key programming switch is a programmable switch which provides the capability
to enable/disable the normal customer spare key programming procedure detailed in the Owner's
Literature. It must read ENABLE if more than 2 keys need to be programmed into the Instrument
Cluster (IC). For additional information, refer to Key Programming Using Two Programmed Keys
See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. This
programmable switch is provided as a convenience for rental company fleets or other fleet
purchasers who may not want the spare key programming procedure available to the vehicle
driver.
NOTE: The spare key programming switch state can be viewed with the IC PID SPAREKEY.
NOTE: If the SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the IC
using Key Programming Using Two Programmed Keys See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key
Programming Using Two Programmed Keys. If the SPAREKEY PID reads DISABLED, the Key
Programming Using Two Programmed Keys procedure will not function. This switch is set to
ENABLE when the vehicle is built. This PID does not affect the Key Programming Using Diagnostic
Equipment, the Spare Key Programming - Unlimited Key Mode or the Spare Key Programming Using Diagnostic Equipment procedures.
1. Insert a programmed Passive Anti-Theft System (PATS) key into the ignition lock cylinder and
turn the key from the OFF position to the ON
position.
2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow
the on-screen instructions to ENTER
SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See:
Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Component Tests and General Diagnostics.
3. NOTE: The default setting of the key programming switch on delivery of all new vehicles is
ENABLED, when viewing the IC PID SPAREKEY.
From the scan tool menu select: "Customer Spare Key Programming Enable" (or "Customer Spare
Key Programming Disable"), and follow the on-screen instructions. "Customer Spare Key Programming Enable" - the spare key programming procedure is accessible.
- "Customer Spare Key Programming Disable" - the spare key programming procedure is not
accessible.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and
Inspection > Key Programming Switch State Control > Page 5013
Key: Testing and Inspection Key Programming Using Diagnostic Equipment
Key Programming Using Diagnostic Equipment
NOTE: This procedure is used when a customer needs keys programmed into the system and
does not have 2 programmed ignition keys available. This procedure is also useful when a
programmed ignition key(s) is lost or the ignition lock cylinder is replaced, and it is desired to erase
key code(s) from the Passive Anti-Theft System (PATS) memory.
NOTE: This procedure erases all programmed ignition keys from the vehicle memory. The vehicle
will not start until a minimum of 2 keys are programmed into the Instrument Cluster (IC).
NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle will start.
NOTE: Two PATS encoded (contains a transponder) keys with the correct mechanical cut must be
available to carry out this procedure. One or both of them may be the customer's original keys.
NOTE: If additional keys are to be programmed, refer to Key Programming Using Two
Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing
and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If
the remaining keys are with the customer and are not available with the vehicle, instruct the
customer to refer to the Owner's Literature for instructions on programming the remaining keys. In
this case, the PID SPAREKEY must be enabled.
NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of
the transceiver does not erase the PATS key codes in the IC.
1. Turn the key from the OFF position to the ON position.
2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow
the on-screen instructions to ENTER
SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See:
Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Component Tests and General Diagnostics.
3. From the scan tool menu select: "Ignition Key Code Erase" and follow the on-screen instructions.
4. Turn the key to the OFF position and disconnect the scan tool.
5. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3
seconds.
6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder.
7. Insert the next PATS key into the ignition lock cylinder and turn the key to the ON position for 3
seconds.
8. The vehicle should now start with both PATS ignition keys.
9. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the
IC), refer to Key Programming Using Two
Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing
and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for
each additional key that needs to be programmed.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and
Inspection > Key Programming Switch State Control > Page 5014
Key: Testing and Inspection Key Programming Using Two Programmed Keys
Key Programming Using Two Programmed Keys
NOTE: This procedure only works if 2 or more programmed ignition keys are available. If 2
programmed keys are not available, refer to Key Programming Using Diagnostic Equipment See:
Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Programming and Relearning/Key Programming Using Diagnostic Equipment.
NOTE: The Instrument Cluster (IC) PID SPAREKEY must be enabled for this procedure to operate.
If this IC PID is not enabled, refer to Key Programming Switch State Control See: Accessories and
Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and
Relearning/Key Programming Switch State Control, then select SPAREKEY programming switch;
ENABLED. The IC PID SPAREKEY is set to ENABLE when the vehicle is built.
NOTE: If the programming procedure is successful, the new key(s) will start the vehicle and the
anti-theft indicator will prove-out for approximately 3 seconds. If the programming procedure is not
successful and the new key(s) does not start the engine, leave the key in the ON position for at
least 3 seconds, then turn the key off. Repeat the key programming procedure from Step 1. If the
failure repeats, refer to Anti-Theft See: Accessories and Optional Equipment/Antitheft and Alarm
Systems/Testing and Inspection in the Diagnosis and Testing to review the DTCs and carry out the
appropriate pinpoint tests.
NOTE: A maximum of 8 Passive Anti-Theft System (PATS) keys can be programmed into the IC
during this programming procedure, but only if the IC PID SPAREKEY is ENABLED.
NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle will start.
NOTE: If the vehicle is in unlimited key mode, this spare key programming procedure still functions.
Any 2 keys that can start the vehicle can be used to program an additional unlimited key.
NOTE: If additional keys are to be programmed, and the remaining keys are with the customer, or
are not available, instruct the customer to refer to the Owner's Literature for instructions on
programming the remaining keys. In this case, the IC PID SPAREKEY must be enabled.
NOTE: If the steps are not carried out as outlined, the programming procedure will end.
NOTE: Ignition keys must have a correct mechanical key cut for the vehicle and must be PATS
encoded keys (contain a transponder).
NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of
the transceiver does not erase the PATS key codes in the IC.
NOTE: When in the unlimited key mode, the N_KEYCODE PID will always read 2 (after the first 2
keys have been programmed), no matter how many keys are programmed to the vehicle.
1. Insert the first programmed key into the ignition lock cylinder and turn the key from the OFF
position to the ON position (maintain the key in the
ON position for a minimum of 3 seconds and less than 10 seconds).
2. Turn the key to the OFF position and remove the first key from the ignition lock cylinder.
3. Within 5 seconds of turning the key to the OFF position, insert the second programmed key into
the ignition lock cylinder and turn the key from
the OFF position to the ON position (maintain the key in the ON position for a minimum of 3
seconds and less than 10 seconds).
4. Turn the key to the OFF position and remove the key from the ignition lock cylinder.
5. Within 10 seconds of turning the key to the OFF position, insert the unprogrammed key (the new
key) into the ignition lock cylinder and turn the
key from the OFF position to the ON position (maintain the key in the ON position for a minimum of
3 seconds and less than 10 seconds).
6. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the
IC), repeat Steps 1-5 for each additional key that
needs to be programmed.
7. Start the vehicle with the new key(s).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and
Inspection > Key Programming Switch State Control > Page 5015
Key: Testing and Inspection Spare Key Programming - Unlimited Key Mode
Spare Key Programming - Unlimited Key Mode
Enabling Unlimited Key Mode
NOTE: Unlimited key mode is intended for use by those customers who need more than 8 keys for
their vehicle.
NOTE: Before programming, the new key(s) must have the correct mechanical cut for the ignition
lock cylinder(s).
NOTE: The unlimited key mode is set up by creating a special, unique unlimited transponder
security key code and programming this key code into all of the vehicle keys so they contain the
same key code.
NOTE: When in the unlimited key mode, the N_KEYCODE PID always reads 2, no matter how
many keys are programmed to the vehicle (after the first 2 keys have been programmed).
1. The customer must choose an 8-digit number (except for 00000000 or 00000001) to be
programmed into all of their vehicles keys (or, to all of the
keys they want programmed to one vehicle). All customer vehicles keys (or all keys for one vehicle)
need to use the same number. Valid digits are 0-9 and the letters A-F.
2. NOTE: If the Instrument Cluster (IC) UNL_KEY_ID PID is not available, unlimited key mode is
turned on, and must be turned off before
viewing the stored code. At this time, unlimited keys may be programmed to the vehicle(s). To
view/change the stored code, follow the procedure for disabling the unlimited key mode below.
Monitor the IC UNL_KEY_ID PID and compare its value against the code chosen in Step 1. It
should not be the same key code.
3. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the
on-screen instructions to ENTER SECURITY
ACCESS. This procedure takes approximately 10 minutes to carry out, during which time the
ignition key must be in the
ON position and the scan tool must be connected to the vehicle. For additional information, refer to
Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm
Systems/Testing and Inspection/Component Tests and General Diagnostics.
4. Once in security access, select: "program unlimited key code" and follow the on-screen
instructions. Enter the 8-digit code chosen by the customer
in Step 1 of this procedure and follow the on-screen instructions.
5. Select: "unlimited key mode ON" and follow the on-screen instructions.
6. Select: "Ignition Key Code Erase" and follow the on-screen instructions.
7. Disconnect the scan tool and turn the ignition key to the OFF position (the key does not need to
be removed at this time).
8. Turn the first Passive Anti-Theft System (PATS) key in the ignition lock cylinder to the ON
position for 3 seconds.
9. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder.
10. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position
for 3 seconds.
11. The vehicle should now start with both PATS keys.
12. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed
Keys See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key
Programming Using Two Programmed Keys for each additional key that needs to be programmed.
Disabling Unlimited Key Mode
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Inspection > Key Programming Switch State Control > Page 5016
NOTE: By disabling the unlimited key mode, the previous access code no longer operates the
vehicle.
1. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the
on-screen instructions to ENTER SECURITY
ACCESS. This procedure takes approximately 10 minutes to carry out, during which time the
ignition key must be in the ON position and the scan tool must be connected to the vehicle. For
additional information, refer to Anti-Theft Security Access See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General
Diagnostics.
2. Select: "unlimited key mode OFF" and follow the on-screen instructions.
3. Select: "Ignition Key Code Erase" and follow the on-screen instructions.
4. Disconnect the scan tool and turn the ignition switch to the OFF position (the key does not need
to be removed at this time).
5. Turn the first PATS key in the ignition lock cylinder to the ON position for 3 seconds.
6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder.
7. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for
3 seconds.
8. NOTE: With the unlimited key mode turned off, a maximum of 8 keys can be programmed into
the Instrument Cluster (IC) using the Key
Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft
and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using
Two Programmed Keys procedure. The IC SPAREKEY PID must be enabled.
If it is desired to program additional key(s), refer to Key Programming Using Two Programmed
Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each
additional key (up to 8 keys, total) that needs to be programmed. The IC SPAREKEY PID must be
enabled.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and
Inspection > Key Programming Switch State Control > Page 5017
Key: Testing and Inspection
Key Programming Switch State Control
Key Programming Switch State Control
NOTE: The spare key programming switch is a programmable switch which provides the capability
to enable/disable the normal customer spare key programming procedure detailed in the Owner's
Literature. It must read ENABLE if more than 2 keys need to be programmed into the Instrument
Cluster (IC). For additional information, refer to Key Programming Using Two Programmed Keys
See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. This
programmable switch is provided as a convenience for rental company fleets or other fleet
purchasers who may not want the spare key programming procedure available to the vehicle
driver.
NOTE: The spare key programming switch state can be viewed with the IC PID SPAREKEY.
NOTE: If the SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the IC
using Key Programming Using Two Programmed Keys See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key
Programming Using Two Programmed Keys. If the SPAREKEY PID reads DISABLED, the Key
Programming Using Two Programmed Keys procedure will not function. This switch is set to
ENABLE when the vehicle is built. This PID does not affect the Key Programming Using Diagnostic
Equipment, the Spare Key Programming - Unlimited Key Mode or the Spare Key Programming Using Diagnostic Equipment procedures.
1. Insert a programmed Passive Anti-Theft System (PATS) key into the ignition lock cylinder and
turn the key from the OFF position to the ON
position.
2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow
the on-screen instructions to ENTER
SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See:
Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Component Tests and General Diagnostics.
3. NOTE: The default setting of the key programming switch on delivery of all new vehicles is
ENABLED, when viewing the IC PID SPAREKEY.
From the scan tool menu select: "Customer Spare Key Programming Enable" (or "Customer Spare
Key Programming Disable"), and follow the on-screen instructions. "Customer Spare Key Programming Enable" - the spare key programming procedure is accessible.
- "Customer Spare Key Programming Disable" - the spare key programming procedure is not
accessible.
Key Programming Using Diagnostic Equipment
Key Programming Using Diagnostic Equipment
NOTE: This procedure is used when a customer needs keys programmed into the system and
does not have 2 programmed ignition keys available. This procedure is also useful when a
programmed ignition key(s) is lost or the ignition lock cylinder is replaced, and it is desired to erase
key code(s) from the Passive Anti-Theft System (PATS) memory.
NOTE: This procedure erases all programmed ignition keys from the vehicle memory. The vehicle
will not start until a minimum of 2 keys are
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and
Inspection > Key Programming Switch State Control > Page 5018
programmed into the Instrument Cluster (IC).
NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle will start.
NOTE: Two PATS encoded (contains a transponder) keys with the correct mechanical cut must be
available to carry out this procedure. One or both of them may be the customer's original keys.
NOTE: If additional keys are to be programmed, refer to Key Programming Using Two
Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing
and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If
the remaining keys are with the customer and are not available with the vehicle, instruct the
customer to refer to the Owner's Literature for instructions on programming the remaining keys. In
this case, the PID SPAREKEY must be enabled.
NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of
the transceiver does not erase the PATS key codes in the IC.
1. Turn the key from the OFF position to the ON position.
2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow
the on-screen instructions to ENTER
SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See:
Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Component Tests and General Diagnostics.
3. From the scan tool menu select: "Ignition Key Code Erase" and follow the on-screen instructions.
4. Turn the key to the OFF position and disconnect the scan tool.
5. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3
seconds.
6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder.
7. Insert the next PATS key into the ignition lock cylinder and turn the key to the ON position for 3
seconds.
8. The vehicle should now start with both PATS ignition keys.
9. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the
IC), refer to Key Programming Using Two
Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing
and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for
each additional key that needs to be programmed.
Key Programming Using Two Programmed Keys
Key Programming Using Two Programmed Keys
NOTE: This procedure only works if 2 or more programmed ignition keys are available. If 2
programmed keys are not available, refer to Key Programming Using Diagnostic Equipment See:
Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Programming and Relearning/Key Programming Using Diagnostic Equipment.
NOTE: The Instrument Cluster (IC) PID SPAREKEY must be enabled for this procedure to operate.
If this IC PID is not enabled, refer to Key Programming Switch State Control See: Accessories and
Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and
Relearning/Key Programming Switch State Control, then select SPAREKEY programming switch;
ENABLED. The IC PID SPAREKEY is set to ENABLE when the vehicle is built.
NOTE: If the programming procedure is successful, the new key(s) will start the vehicle and the
anti-theft indicator will prove-out for approximately 3 seconds. If the programming procedure is not
successful and the new key(s) does not start the engine, leave the key in the ON position for at
least 3 seconds, then turn the key off. Repeat the key programming procedure from Step 1. If the
failure repeats, refer to Anti-Theft See: Accessories and Optional Equipment/Antitheft and Alarm
Systems/Testing and Inspection in the Diagnosis and Testing to review the DTCs and carry out the
appropriate pinpoint tests.
NOTE: A maximum of 8 Passive Anti-Theft System (PATS) keys can be programmed into the IC
during this programming procedure, but only if the IC PID SPAREKEY is ENABLED.
NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle will start.
NOTE: If the vehicle is in unlimited key mode, this spare key programming procedure still functions.
Any 2 keys that can start the vehicle can be used to program an additional unlimited key.
NOTE: If additional keys are to be programmed, and the remaining keys are with the customer, or
are not available, instruct the customer to refer to the
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and
Inspection > Key Programming Switch State Control > Page 5019
Owner's Literature for instructions on programming the remaining keys. In this case, the IC PID
SPAREKEY must be enabled.
NOTE: If the steps are not carried out as outlined, the programming procedure will end.
NOTE: Ignition keys must have a correct mechanical key cut for the vehicle and must be PATS
encoded keys (contain a transponder).
NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of
the transceiver does not erase the PATS key codes in the IC.
NOTE: When in the unlimited key mode, the N_KEYCODE PID will always read 2 (after the first 2
keys have been programmed), no matter how many keys are programmed to the vehicle.
1. Insert the first programmed key into the ignition lock cylinder and turn the key from the OFF
position to the ON position (maintain the key in the
ON position for a minimum of 3 seconds and less than 10 seconds).
2. Turn the key to the OFF position and remove the first key from the ignition lock cylinder.
3. Within 5 seconds of turning the key to the OFF position, insert the second programmed key into
the ignition lock cylinder and turn the key from
the OFF position to the ON position (maintain the key in the ON position for a minimum of 3
seconds and less than 10 seconds).
4. Turn the key to the OFF position and remove the key from the ignition lock cylinder.
5. Within 10 seconds of turning the key to the OFF position, insert the unprogrammed key (the new
key) into the ignition lock cylinder and turn the
key from the OFF position to the ON position (maintain the key in the ON position for a minimum of
3 seconds and less than 10 seconds).
6. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the
IC), repeat Steps 1-5 for each additional key that
needs to be programmed.
7. Start the vehicle with the new key(s).
Spare Key Programming - Unlimited Key Mode
Spare Key Programming - Unlimited Key Mode
Enabling Unlimited Key Mode
NOTE: Unlimited key mode is intended for use by those customers who need more than 8 keys for
their vehicle.
NOTE: Before programming, the new key(s) must have the correct mechanical cut for the ignition
lock cylinder(s).
NOTE: The unlimited key mode is set up by creating a special, unique unlimited transponder
security key code and programming this key code into all of the vehicle keys so they contain the
same key code.
NOTE: When in the unlimited key mode, the N_KEYCODE PID always reads 2, no matter how
many keys are programmed to the vehicle (after the first 2 keys have been programmed).
1. The customer must choose an 8-digit number (except for 00000000 or 00000001) to be
programmed into all of their vehicles keys (or, to all of the
keys they want programmed to one vehicle). All customer vehicles keys (or all keys for one vehicle)
need to use the same number. Valid digits are 0-9 and the letters A-F.
2. NOTE: If the Instrument Cluster (IC) UNL_KEY_ID PID is not available, unlimited key mode is
turned on, and must be turned off before
viewing the stored code. At this time, unlimited keys may be programmed to the vehicle(s). To
view/change the stored code, follow the procedure for disabling the unlimited key mode below.
Monitor the IC UNL_KEY_ID PID and compare its value against the code chosen in Step 1. It
should not be the same key code.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and
Inspection > Key Programming Switch State Control > Page 5020
3. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the
on-screen instructions to ENTER SECURITY
ACCESS. This procedure takes approximately 10 minutes to carry out, during which time the
ignition key must be in the
ON position and the scan tool must be connected to the vehicle. For additional information, refer to
Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm
Systems/Testing and Inspection/Component Tests and General Diagnostics.
4. Once in security access, select: "program unlimited key code" and follow the on-screen
instructions. Enter the 8-digit code chosen by the customer
in Step 1 of this procedure and follow the on-screen instructions.
5. Select: "unlimited key mode ON" and follow the on-screen instructions.
6. Select: "Ignition Key Code Erase" and follow the on-screen instructions.
7. Disconnect the scan tool and turn the ignition key to the OFF position (the key does not need to
be removed at this time).
8. Turn the first Passive Anti-Theft System (PATS) key in the ignition lock cylinder to the ON
position for 3 seconds.
9. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder.
10. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position
for 3 seconds.
11. The vehicle should now start with both PATS keys.
12. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed
Keys See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key
Programming Using Two Programmed Keys for each additional key that needs to be programmed.
Disabling Unlimited Key Mode
NOTE: By disabling the unlimited key mode, the previous access code no longer operates the
vehicle.
1. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the
on-screen instructions to ENTER SECURITY
ACCESS. This procedure takes approximately 10 minutes to carry out, during which time the
ignition key must be in the ON position and the scan tool must be connected to the vehicle. For
additional information, refer to Anti-Theft Security Access See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General
Diagnostics.
2. Select: "unlimited key mode OFF" and follow the on-screen instructions.
3. Select: "Ignition Key Code Erase" and follow the on-screen instructions.
4. Disconnect the scan tool and turn the ignition switch to the OFF position (the key does not need
to be removed at this time).
5. Turn the first PATS key in the ignition lock cylinder to the ON position for 3 seconds.
6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder.
7. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for
3 seconds.
8. NOTE: With the unlimited key mode turned off, a maximum of 8 keys can be programmed into
the Instrument Cluster (IC) using the Key
Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft
and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using
Two Programmed Keys procedure. The IC SPAREKEY PID must be enabled.
If it is desired to program additional key(s), refer to Key Programming Using Two Programmed
Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each
additional key (up to 8 keys, total) that needs to be programmed. The IC SPAREKEY PID must be
enabled.
Spare Key Programming - Using Diagnostic Equipment
Spare Key Programming - Using Diagnostic Equipment
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and
Inspection > Key Programming Switch State Control > Page 5021
NOTE: This procedure is used when a customer needs to have an additional key programmed into
the vehicle without erasing stored key codes, but does not have 2 programmed keys available. This
procedure is also useful when attempting to determine if an ignition key is damaged, as a new key
can be installed without erasing keys or without having 2 programmed keys available.
NOTE: Before programming, the new key must have the correct mechanical cut for the ignition lock
cylinder.
NOTE: If 8 keys are already programmed, this procedure does not allow any more ignition keys to
be programmed. The number of keys that are programmed into the Passive Anti-Theft System
(PATS) can be determined by viewing the Instrument Cluster (IC) PID N_KEYCODE.
NOTE: When in the unlimited key mode, the N_KEYCODE PID will always read 2 (after the first 2
keys have been programmed), no matter how many keys are programmed to the vehicle.
1. Turn the unprogrammed PATS key from the OFF position to the ON position.
2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow
the on-screen instructions to ENTER
SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See:
Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Component Tests and General Diagnostics.
3. NOTE: Make sure the selection made is "PROGRAM" (Program additional ignition key). If the
"ERASE" (Ignition Key Code Erase) selection is
made, all of the keys will be erased from the system.
From the scan tool menu select: "Program additional ignition key" and follow the on-screen
instructions.
4. Turn the key to the OFF position and disconnect the scan tool.
5. Start the vehicle with the new PATS key. The vehicle will now start with the new PATS key and
also with the original PATS keys.
Passive Anti-Theft System (PATS) Parameter Reset
Passive Anti-Theft System (PATS) Parameter Reset
NOTE: When using the Integrated Diagnostic System (IDS), the Instrument Cluster (IC) and the
PCM parameters are reset at the same time.
1. Turn the key from the OFF position to the ON position.
2. From the scan tool, follow the on-screen instructions to ENTER SECURITY ACCESS. For
additional information, refer to Anti-Theft Security
Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Component Tests and General Diagnostics .
3. From the scan tool, select: Parameter Reset and follow the on-screen instructions.
4. NOTE: If the IC was replaced, follow Steps 4-9. If the IC and the PCM were replaced, follow
Steps 4-9. If only the PCM was replaced, go to Step
9.
From the scan tool, select: Ignition Key Code Erase and follow the on-screen instructions.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and
Inspection > Key Programming Switch State Control > Page 5022
5. Turn the key to the OFF position and disconnect the scan tool.
6. Turn the key to the ON position for a minimum of 3 seconds.
7. Turn the key to the OFF position and remove the key.
8. Insert the second key into the ignition lock cylinder and turn the key to the ON position for a
minimum of 3 seconds.
9. Both keys will now start the vehicle.
10. If more keys are required to be programmed, refer to Key Programming Using Two
Programmed Keys See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key
Programming Using Two Programmed Keys.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations
Neutral Safety Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations > Page 5026
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Locations > Page 5027
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > General Specifications
Starter Motor: Specifications General Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > General Specifications > Page 5032
Starter Motor: Specifications Torque Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 5033
Starter Motor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Specifications > Page 5034
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Specifications > Page 5035
Starter Motor: Diagrams
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Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 5036
Starter Motor: Service and Repair
Starter Motor - 4.0L SOHC
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 motor solenoid terminal cover.
4. Remove the B-terminal nut and disconnect the cable.
- To install, tighten to 12 Nm (106 lb-in).
5. Remove the S-terminal nut and disconnect the cable.
- To install, tighten to 6 Nm (53 lb-in).
6. Remove the nut and position the ground cable aside.
- To install, tighten to 20 Nm (177 lb-in).
7. Remove the bolt, the stud bolt and the starter.
- To install, tighten to 25 Nm (18 lb-ft).
8. To install, reverse the removal procedure.
- Tighten the upper bolt before tightening the lower fastener.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Starter Relay
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Starter Relay > Page 5041
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and
Inspection > Starter Relay
Starter Relay: Testing and Inspection Starter Relay
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and
Inspection > Starter Relay > Page 5044
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and
Inspection > Starter Relay > Page 5045
Starter Relay: Testing and Inspection Run/Start Relay
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and
Inspection > Starter Relay > Page 5046
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Power Point, Rear
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Power Point, Rear > Page 5052
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Power Point, Rear > Page 5053
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Power Point, Rear > Page 5054
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Service and Repair > Pickup Bed Power Point
Auxiliary Power Outlet: Service and Repair Pickup Bed Power Point
Pickup Bed Power Point
Removal and Installation
1. Remove the 4 screws and the power point receptacle from the pickup bed side.
2. Disconnect the power point receptacle electrical connector and remove the power point
receptacle.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Service and Repair > Pickup Bed Power Point > Page 5057
Auxiliary Power Outlet: Service and Repair Power Point
Power Point
Removal
NOTE: Power point cover may differ depending on location.
1. Open the power point cover.
2. Install the Power Point Socket Remover in one of the power point socket slots.
3. Position the Power Point Socket Remover so that it engages in the adjacent slot.
4. Using the Power Point Socket Remover, pull the power point socket out of the retainer.
5. Disconnect the electrical connector.
Installation
1. Connect the electrical connector.
2. Slide the power point socket into the retainer.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Locations
Circuit Breaker: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Locations > Page 5061
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Locations > Page 5062
Circuit Breaker: Application and ID
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Locations > Page 5063
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Diagrams > Ignition Transformer Capacitor 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 5068
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 5069
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5074
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5075
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5076
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5077
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5078
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5079
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5080
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5081
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5082
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5083
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 5086
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5087
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5088
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5089
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5090
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5091
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5092
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5093
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5094
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5095
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Battery Junction Box (BJB)
Fuse Block: Locations Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Battery Junction Box (BJB) > Page 5100
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Battery Junction Box (BJB) > Page 5101
Fuse Block: Locations Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Battery Junction Box (BJB) > Page 5102
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Battery Junction Box (BJB) > Page 5103
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Battery Junction Box (BJB) > Page 5104
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Battery Junction Box (BJB) > Page 5105
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Battery Junction Box (BJB) > Page 5106
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5109
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5110
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5111
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5112
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
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5113
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery 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 loose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5114
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5115
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5116
Symbols (Part 4)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5117
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5118
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.
Defective insulation stripping
1 = Proper crimp
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5119
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5120
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5121
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5122
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5123
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.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5124
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 (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5125
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5126
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5127
Fuse Block: Connector Views
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5128
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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> Diagrams > Diagram Information and Instructions > Page 5129
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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> Diagrams > Diagram Information and Instructions > Page 5130
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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> Diagrams > Diagram Information and Instructions > Page 5131
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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> Diagrams > Diagram Information and Instructions > Page 5132
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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> Diagrams > Diagram Information and Instructions > Page 5133
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component
Information > Testing and Inspection > Page 5137
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component
Information > Testing and Inspection > Page 5141
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410
Multiple Junction Connector: Diagrams C110-C410
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5146
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5147
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5148
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5149
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5150
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5151
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5152
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5153
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5154
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5155
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5156
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5157
Part 3
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5158
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5159
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5160
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5161
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5162
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5163
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5164
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5165
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5166
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5167
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5168
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5169
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5170
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5171
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5172
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5173
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5174
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5175
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5176
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5177
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5178
Multiple Junction Connector: Diagrams C411-C4004
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5179
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5180
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5181
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5182
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5183
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5184
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5185
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5186
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5187
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5188
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5189
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5190
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5191
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5192
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5193
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5194
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5195
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5196
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5197
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5198
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5199
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5200
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5201
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5202
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5203
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C410 > Page 5204
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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)
Removal
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module >
Component Information > Service and Repair > Page 5208
NOTICE: If the SJB is dropped, damage to the internal components may occur. A new SJB must
be installed.
NOTICE: 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.
NOTE: 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.
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. NOTICE: 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. 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 Remote Keyless Entry (RKE) transmitters may
be required to be present in order to program the RKE transmitters to the new SJB.
1. 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module >
Component Information > Service and Repair > Page 5209
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 (177 lb-in).
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.
NOTE: 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.
Download the SJB configuration information from the scan tool into the new SJB. See: Accessories
and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry
Transmitter/Testing and Inspection/Remote Keyless Entry (RKE) Transmitter Programming
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.
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 DTC C2780.
Carry out the SJB self-test (must include an on-demand) by clearing DTCs, and then retrieving
DTCs to confirm all DTCs have been cleared.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations > Page 5213
Power Distribution Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations > Page 5214
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations > Page 5215
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 > Page 5220
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 > Page 5224
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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)
Removal
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5228
NOTICE: If the SJB is dropped, damage to the internal components may occur. A new SJB must
be installed.
NOTICE: 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.
NOTE: 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.
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. NOTICE: 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. 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 Remote Keyless Entry (RKE) transmitters may
be required to be present in order to program the RKE transmitters to the new SJB.
1. 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5229
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 (177 lb-in).
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.
NOTE: 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.
Download the SJB configuration information from the scan tool into the new SJB. See: Accessories
and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry
Transmitter/Testing and Inspection/Remote Keyless Entry (RKE) Transmitter Programming
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.
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 DTC C2780.
Carry out the SJB self-test (must include an on-demand) by clearing DTCs, and then retrieving
DTCs to confirm all DTCs have been cleared.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5233
Power Distribution Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5234
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5235
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB)
Relay Box: Locations Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5240
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5241
Relay Box: Locations Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5242
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5243
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5244
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5245
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5246
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5249
Relay Box: Diagrams Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5250
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5251
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5252
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5253
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5254
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB)
Relay Box: Application and ID Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5257
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5258
Relay Box: Application and ID Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5259
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Battery Junction Box (BJB)
Relay Box: Locations Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Battery Junction Box (BJB) > Page 5264
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Battery Junction Box (BJB) > Page 5265
Relay Box: Locations Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Battery Junction Box (BJB) > Page 5266
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Battery Junction Box (BJB) > Page 5267
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Battery Junction Box (BJB) > Page 5268
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Battery Junction Box (BJB) > Page 5269
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Battery Junction Box (BJB) > Page 5270
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 5273
Relay Box: Diagrams Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 5274
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 5275
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 5276
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 5277
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 5278
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Battery Junction Box (BJB)
Relay Box: Application and ID Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Battery Junction Box (BJB) > Page 5281
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Battery Junction Box (BJB) > Page 5282
Relay Box: Application and ID Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Battery Junction Box (BJB) > Page 5283
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Power Point, Rear
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Power Point, Rear > Page 5289
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Power Point, Rear > Page 5290
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Power Point, Rear > Page 5291
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and
Repair > Pickup Bed Power Point
Auxiliary Power Outlet: Service and Repair Pickup Bed Power Point
Pickup Bed Power Point
Removal and Installation
1. Remove the 4 screws and the power point receptacle from the pickup bed side.
2. Disconnect the power point receptacle electrical connector and remove the power point
receptacle.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and
Repair > Pickup Bed Power Point > Page 5294
Auxiliary Power Outlet: Service and Repair Power Point
Power Point
Removal
NOTE: Power point cover may differ depending on location.
1. Open the power point cover.
2. Install the Power Point Socket Remover in one of the power point socket slots.
3. Position the Power Point Socket Remover so that it engages in the adjacent slot.
4. Using the Power Point Socket Remover, pull the power point socket out of the retainer.
5. Disconnect the electrical connector.
Installation
1. Connect the electrical connector.
2. Slide the power point socket into the retainer.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations
Circuit Breaker: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page
5298
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page
5299
Circuit Breaker: Application and ID
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page
5300
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Diagrams > Ignition Transformer Capacitor 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Diagrams > Ignition Transformer Capacitor 1 > Page 5305
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Diagrams > Ignition Transformer Capacitor 1 > Page 5306
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5311
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5312
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5313
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5314
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5315
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5316
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5317
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5318
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5319
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5320
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5323
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5324
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5325
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5326
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5327
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5328
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5329
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5330
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5331
Fuse
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5332
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery
Junction Box (BJB)
Fuse Block: Locations Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery
Junction Box (BJB) > Page 5337
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery
Junction Box (BJB) > Page 5338
Fuse Block: Locations Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery
Junction Box (BJB) > Page 5339
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery
Junction Box (BJB) > Page 5340
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery
Junction Box (BJB) > Page 5341
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery
Junction Box (BJB) > Page 5342
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery
Junction Box (BJB) > Page 5343
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions
Fuse Block: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5346
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5347
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5348
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5349
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
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5350
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery 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 loose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5351
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5352
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5353
Symbols (Part 4)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5354
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5355
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.
Defective insulation stripping
1 = Proper crimp
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5356
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5357
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5358
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5359
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5360
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.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5361
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 (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5362
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5363
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5364
Fuse Block: Connector Views
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5365
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5366
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5367
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5368
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5369
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5370
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and
Inspection > Page 5374
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and
Inspection > Page 5378
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410
Multiple Junction Connector: Diagrams C110-C410
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5383
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5384
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5385
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5386
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5387
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5388
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5389
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5390
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5391
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5392
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5393
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5394
Part 3
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5395
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5396
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5397
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5398
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5399
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5400
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5401
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5402
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5403
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5404
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5405
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Diagrams > C110-C410 > Page 5406
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Diagrams > C110-C410 > Page 5407
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Diagrams > C110-C410 > Page 5408
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Diagrams > C110-C410 > Page 5409
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5410
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5411
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5412
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5413
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5414
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5415
Multiple Junction Connector: Diagrams C411-C4004
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5416
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5417
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5418
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5419
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5420
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5421
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5422
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5423
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5424
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5425
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5426
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5427
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5428
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5429
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5430
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5431
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5432
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5433
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5434
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5435
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5436
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5437
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5438
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5439
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5440
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C410 > Page 5441
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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)
Removal
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service
and Repair > Page 5445
NOTICE: If the SJB is dropped, damage to the internal components may occur. A new SJB must
be installed.
NOTICE: 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.
NOTE: 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.
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. NOTICE: 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. 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 Remote Keyless Entry (RKE) transmitters may
be required to be present in order to program the RKE transmitters to the new SJB.
1. 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service
and Repair > Page 5446
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 (177 lb-in).
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.
NOTE: 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.
Download the SJB configuration information from the scan tool into the new SJB. See: Accessories
and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry
Transmitter/Testing and Inspection/Remote Keyless Entry (RKE) Transmitter Programming
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.
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 DTC C2780.
Carry out the SJB self-test (must include an on-demand) by clearing DTCs, and then retrieving
DTCs to confirm all DTCs have been cleared.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
> Page 5450
Power Distribution Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
> Page 5451
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
> Page 5452
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
ISO Relay > Component Information > Testing and Inspection > Page 5457
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini
ISO Relay > Component Information > Testing and Inspection > Page 5461
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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)
Removal
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Module > Component Information > Service and Repair > Page 5465
NOTICE: If the SJB is dropped, damage to the internal components may occur. A new SJB must
be installed.
NOTICE: 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.
NOTE: 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.
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. NOTICE: 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. 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 Remote Keyless Entry (RKE) transmitters may
be required to be present in order to program the RKE transmitters to the new SJB.
1. 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Module > Component Information > Service and Repair > Page 5466
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 (177 lb-in).
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.
NOTE: 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.
Download the SJB configuration information from the scan tool into the new SJB. See: Accessories
and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry
Transmitter/Testing and Inspection/Remote Keyless Entry (RKE) Transmitter Programming
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.
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 DTC C2780.
Carry out the SJB self-test (must include an on-demand) by clearing DTCs, and then retrieving
DTCs to confirm all DTCs have been cleared.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Page 5470
Power Distribution Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Page 5471
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Page 5472
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Battery Junction Box (BJB)
Relay Box: Locations Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5477
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5478
Relay Box: Locations Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5479
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5480
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5481
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5482
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5483
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5486
Relay Box: Diagrams Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5487
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5488
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5489
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5490
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5491
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Battery Junction Box (BJB)
Relay Box: Application and ID Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5494
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5495
Relay Box: Application and ID Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5496
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery
Junction Box (BJB)
Relay Box: Locations Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery
Junction Box (BJB) > Page 5501
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery
Junction Box (BJB) > Page 5502
Relay Box: Locations Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery
Junction Box (BJB) > Page 5503
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery
Junction Box (BJB) > Page 5504
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery
Junction Box (BJB) > Page 5505
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery
Junction Box (BJB) > Page 5506
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery
Junction Box (BJB) > Page 5507
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB)
Relay Box: Diagrams Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 5510
Relay Box: Diagrams Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 5511
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 5512
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 5513
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 5514
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 5515
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Battery Junction Box (BJB)
Relay Box: Application and ID Battery Junction Box (BJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Battery Junction Box (BJB) > Page 5518
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Battery Junction Box (BJB) > Page 5519
Relay Box: Application and ID Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Battery Junction Box (BJB) > Page 5520
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications
Alignment: Specifications Alignment Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications > Page 5526
Alignment: Specifications Ball Joint Deflection, Ride Height, Thrust Angle, and Vehicle Lean
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications > Page 5527
Alignment: Specifications Torque Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Camber
Alignment: Description and Operation Camber
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Camber > Page 5530
Alignment: Description and Operation Caster
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.
Caster
Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed
from the side. The caster specifications will give the vehicle the best directional stability
characteristics when loaded and driven. The caster setting is not related to tire wear.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Camber > Page 5531
Alignment: Description and Operation Drift/Pull
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.
Drift/Pull
Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep
the vehicle going straight.
Drift describes what a vehicle with this condition does with hands off the steering wheel.
- A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.
- Drift/pull may be induced by conditions external to the vehicle, such as wind or road camber.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Camber > Page 5532
Alignment: Description and Operation Nibble
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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Camber > Page 5533
Alignment: Description and Operation
Camber
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
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.
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.
Drift/Pull
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Camber > Page 5534
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.
Nibble
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.
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
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.
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.
Shimmy
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.
Shimmy
Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel
resulting from large, side-to-side (lateral) tire/wheel movements.
Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire
contacts pot holes or irregularities in the road surface.
Toe
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.
Toe
Positive Toe (Toe In)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Camber > Page 5535
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.
Incorrect Thrust Angle (Dogtracking)
Wander
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.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel
corrections to maintain a straight path down a level road.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: A caster split adjustment can be made by loosening the LF lower arm rearward nut and
adjusting the rear of the LF lower arm.
Remove and discard the LF lower control arm rearward nut.
5. NOTE: Do not fully tighten the nut and bolt at this time.
Install a new LF lower 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.
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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 5538
Alignment: Service and Repair Ride Height Measurement
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 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 2).
3. Position the surface gauge on the same flat, level surface as used in Step 1, adjust the gauge
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 3).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 5539
5. Subtract measurement 3 from measurement 2 to obtain the front ride height.
- Refer to Specifications.
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 2).
2. Measure the distance between the flat level surface and the center of the shock absorber lower
bolt (measurement 3).
3. Subtract measurement 3 from measurement 2 to obtain the rear ride height.
- Refer to Specifications.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 5540
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. NOTICE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 5541
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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 5542
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 in) 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.
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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5548
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power
Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
Engine Control Components
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 EPC
pressure during increased engine load, for example during parking maneuvers.
Typical Power Steering Pressure (PSP) Switch
Typical Power Steering Pressure (PSP) Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power
Steering Pressure (PSP) Switch > Page 5551
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
Engine Control Components
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 EPC pressure during increased engine load, for example, during
parking maneuvers.
Typical Power Steering Pressure (PSP) Sensor
Typical Power Steering Pressure (PSP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 5555
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 5556
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 5561
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 5562
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 See: Wheels and Tires/Tire Monitoring
System/Testing and Inspection/Programming and Relearning.
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire
Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and
appliance operation, cellular telephones, remote transmitters, power inverters and portable
entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to
activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not
respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate
the same sensor again.
NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not
recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and
the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire
procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for
front and rear tires, tire rotation will not affect the system.
1. Turn the ignition switch to the OFF position, then press and release the brake pedal.
2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
3. Press and release the brake pedal.
4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
- The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully. If equipped, the message center will display TRAIN LF TIRE.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in
place 180 degrees from the valve stem.
Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from
the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The
horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5568
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall opposite (180 degrees) from the
valve stem and press and release the test button to train the RF tire pressure sensor.
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 identifiers 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 carry out
the SJB On-Demand Self Test.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5569
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 Tire Pressure Monitor 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 Tire Pressure Monitor 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. See: Wheels and Tires/Tire Monitoring System/Testing and
Inspection/Symptom Related Diagnostic Procedures
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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. NOTICE: 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. For additional information, refer to Wheel and Tire See: Wheels
and Tires/Service and Repair/Overhaul.
2. NOTICE: 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.
3. NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5572
4. Remove the sensor.
Assembly
1. NOTICE: 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.
3. NOTICE: 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. For additional information, refer to Wheel and Tire See: Wheels and
Tires/Service and Repair/Overhaul.
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 See: Wheels and Tires/Tire Monitoring System/Testing and
Inspection/Monitors, Trips, Drive Cycles and Readiness Codes.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5573
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
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 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 See: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5574
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 in) 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. NOTICE: 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.
Using wheel and tire cleaner, clean the area where the sensor and cradle are to be installed.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5575
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. NOTICE: 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 in) away from the sensor and tighten the worm gear.
- Tighten to 3 Nm (27 lb-in).
6. NOTICE: 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. For additional information, refer to Wheel and Tire. See: Wheels and
Tires/Service and Repair/Overhaul
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. See: Wheels and Tires/Tire Monitoring System/Testing and
Inspection/Monitors, Trips, Drive Cycles and Readiness Codes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Wheel Knuckle
Removal and Installation
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 5580
NOTICE: 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. NOTICE: 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 the new bolts 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-in).
7. Remove and discard the tie-rod end nut.
- To install, tighten the new nut to 103 Nm (76 lb-ft).
8. NOTICE: Do not use a hammer to separate the tie rod from the wheel knuckle or damage to the
wheel knuckle can result.
NOTICE: Do not damage the tie-rod boot while installing the C-Frame and Screw.
Using the C-Frame and Screw, separate the tie-rod end from the wheel knuckle.
9. Remove and discard the lower ball joint nut.
- To install, tighten the new nut to 150 Nm (111 lb-ft).
10. NOTICE: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
NOTICE: Do not damage the ball joint boot while installing the 2-Jaw Puller.
Using the 2-Jaw Puller, separate the lower ball joint from the wheel knuckle.
11. Remove and discard the upper ball joint nut.
- To install, tighten the new nut to 55 Nm (41 lb-ft).
12. NOTICE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 5581
NOTICE: Do not damage the ball joint boot while installing the C-Frame and Screw.
Using the C-Frame and Screw, separate the upper ball joint and remove the wheel knuckle.
13. To install, reverse the removal procedure.
- Check and, if necessary, align the front end.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
NOTICE: 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 reservoir cap. Check the fluid.
2. Raise the front wheels off the floor.
3. Tightly insert the Power Steering Evacuation Cap into the reservoir and connect the Vacuum
Pump Kit.
4. Start the engine.
5. Using the Vacuum Pump Kit, apply vacuum and maintain the maximum vacuum of 68-85 kPa
(20-25 in-Hg).
- If the Vacuum Pump Kit does not maintain vacuum, check the power steering system for leaks
before proceeding. For additional information, refer to Power Steering Fluid Leak Test. See:
Testing and Inspection/Component Tests and General Diagnostics/Power Steering Fluid Leak Test
6. If equipped with Hydro-Boost(R), apply the brake pedal 4 times.
7. NOTICE: 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 Kit and the Power Steering Evacuation
Cap.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair > Page 5586
10. NOTE: Do not overfill the reservoir.
Fill the reservoir.
- Use approved transmission fluid.
11. Start the engine.
12. Install the Power Steering Evacuation Cap and the Vacuum Pump Kit. Apply and maintain the
maximum vacuum of 68-85 kPa (20-25 in-Hg).
13. NOTICE: 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 Kit and the Power
Steering Evacuation Cap.
15. NOTE: Do not overfill the reservoir.
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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications > Capacity Specifications
Power Steering Fluid: Capacity Specifications
Fill between the MIN and MAX lines on reservoir
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications > Capacity Specifications > Page 5591
Power Steering Fluid: Fluid Type 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 (V6-4.0L (2009))
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
NOTE: 4.0L engine shown, 4.6L engine similar.
Removal and Installation
NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Service and Repair > Page 5595
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 (159 lb-in).
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.
11. Fill the power steering system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
NOTE: 4.0L engine shown, 4.6L engine similar.
Removal and Installation
NOTICE: 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-in).
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.
7. Fill the power steering system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
NOTE: 4.6L engine shown, 4.0L engine similar.
Removal
NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Page 5602
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the power steering pump pulley. For additional information, refer to Power Steering
Pump Pulley - 4.0L See: Power Steering
Pump/Service and Repair/Power Steering Pump Pulley or Power Steering Pump Pulley - 4.6L See:
Power Steering Pump/Service and Repair/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.
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: A new Teflon(R) seal must be installed.
Using the Teflon(R) Seal Installer Set, 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 (97 lb-in).
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 (106 lb-in).
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. For additional information, refer to Power Steering Pump
Pulley - 4.0L See: Power Steering Pump/Service
and Repair/Power Steering Pump Pulley or Power Steering Pump Pulley - 4.6L See: Power
Steering Pump/Service and Repair/Power Steering Pump Pulley.
9. Fill the power steering system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump
Power Steering Pump: Service and Repair Power Steering Pump
Power Steering Pump - 4.0L
Removal
NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 5607
2. With the vehicle in NEUTRAL, position it on a hoist.
3. Remove the power steering pump pulley. For additional information, refer to Power Steering
Pump Pulley - 4.0L See: Power Steering Pump
Pulley.
4. Remove the pressure line bracket-to-engine bolt.
5. Remove the power steering pump supply hose bracket bolt.
6. Release the power steering pump supply hose clamp and disconnect the hose.
7. Disconnect the pressure line-to-pump fitting.
- Remove and discard the Teflon(R) seal.
8. Remove the 3 bolts and the power steering pump.
Installation
1. NOTE: A new Teflon(R) seal must be installed.
Using the Teflon(R) Seal Installer Set, install a new Teflon(R) seal to the pressure line fitting.
2. Position the power steering pump and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
3. Connect the pressure line-to-pump fitting.
- Tighten to 65 Nm (48 lb-ft).
4. Connect the power steering pump supply hose.
5. Install the power steering pump supply hose bracket bolt.
- Tighten to 11 Nm (97 lb-in).
6. Install the pressure line bracket-to-engine bolt.
- Tighten to 11 Nm (97 lb-in).
7. Install the power steering pump pulley. For additional information, refer to Power Steering Pump
Pulley - 4.0L See: Power Steering Pump Pulley.
8. Fill the power steering system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 5608
Power Steering Pump: Service and Repair Power Steering Pump Pulley
Power Steering Pump Pulley - 4.0L
Removal and Installation
1. Disconnect the fan clutch electrical connector, remove the fan clutch wiring harness bracket bolt
and position the harness aside.
- To install, tighten to 7 Nm (62 lb-in).
2. Loosen the 3 power steering pump pulley bolts.
3. Rotate the tensioner and remove the engine accessory drive belt from the power steering pump
pulley.
4. Remove the 3 bolts and the power steering pump pulley.
- To install, tighten to 25 Nm (18 lb-ft).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering
Pressure Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering
Pressure Switch > Component Information > Locations > Page 5613
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering
Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
Engine Control Components
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 EPC
pressure during increased engine load, for example during parking maneuvers.
Typical Power Steering Pressure (PSP) Switch
Typical Power Steering Pressure (PSP) Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering
Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page
5616
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
Engine Control Components
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 EPC pressure during increased engine load, for example, during
parking maneuvers.
Typical Power Steering Pressure (PSP) Sensor
Typical Power Steering Pressure (PSP) Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
> Component Information > Locations
Steering Angle Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
> Component Information > Locations > Page 5620
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
> Component Information > Locations > Page 5621
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Locations
Steering Angle Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Locations > Page 5625
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Locations > Page 5626
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Depowering Procedure
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
may result in serious personal injury.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
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(R) and
cause serious personal injury or death.
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (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 RCM fuse 17 (10A) from the SJB.
For additional information, refer to the Wiring Diagram.
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 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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
5632
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 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 an 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 (V6-4.0L (2009))
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
5633
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Deactivation and Reactivation
Supplemental Restraint System (SRS) Deactivation and Reactivation
Deactivation
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
may result in serious personal injury.
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.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
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.
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
All vehicles
1. Turn all vehicle accessories OFF.
2. Turn the ignition switch OFF.
3. At the Smart Junction Box (SJB), located below the LH side of the instrument panel, remove the
cover and RCM fuse 17 (10A) from the SJB. For
additional information, refer to the Wiring Diagrams.
4. Turn the ignition switch 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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
5634
7. Remove the 2 driver air bag module bolts (1 shown).
8. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag
module.
9. Open and lower the glove compartment door.
10. Detach the wiring retainer, remove the 4 bolts and passenger air bag module heat shield.
11. NOTE: The canister vent and adaptive tether do not require deactivation.
Disconnect the LH side passenger air bag module electrical connector.
12. Under the rear of the passenger seat, detach the passenger seat side air bag module electrical
connector from the seat track bracket. Disengage the
passenger seat side air bag module electrical connector locking clip, release the tab and
disconnect the passenger seat side air bag module electrical connector.
Explorer and Mountaineer vehicles
13. Release and position aside the passenger side C-pillar trim panel.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
5635
14. Disconnect the passenger side safety canopy module electrical connector.
15. Release and position aside the driver side C-pillar trim panel.
16. Disconnect the driver side safety canopy module electrical connector.
Explorer Sport Trac vehicles
17. Remove the driver and passenger side upper C-pillar trim panels.
18. Disconnect the passenger side safety canopy module electrical connector.
19. Disconnect the driver side safety canopy module electrical connector.
All vehicles
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
5636
20. Under driver seat, the rear of the slide and disengage the driver seat side air bag module
electrical connector locking clip, release the tab and
disconnect the driver seat side air bag module electrical connector.
21. Install the RCM fuse 17 (10A) to the SJB.
22. 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. Connect the driver seat side air bag module electrical connector and engage the seat side air
bag electrical connector locking clip.
Explorer Sport Trac vehicles
4. Connect the driver side safety canopy module electrical connector.
5. Connect the passenger side safety canopy module electrical connector.
6. Install the driver and passenger upper C-pillar trim panels.
Explorer and Mountaineer vehicles
7. Connect the driver side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
5637
8. Install the driver side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
9. Connect the passenger side safety canopy module electrical connector.
10. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles
11. Connect the passenger seat side air bag module electrical connector and engage the seat side
air bag electrical connector locking clip. Attach the
passenger seat side air bag module electrical connector to the seat track bracket.
12. Connect the LH side passenger air bag module electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
5638
13. Install the passenger air bag module heat shield and 4 bolts. Attach the wiring retainer.
14. NOTICE: 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.
15. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
16. Turn the ignition switch from OFF to ON.
17. Install RCM fuse 17 (10A) to the SJB and install the cover.
18. 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.
19. 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 an 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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair
Steering Gear: Service and Repair
Steering Gear
Steering Gear (View 1 of 2)
Steering Gear (View 2 of 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Page 5642
Removal and Installation
All vehicles
NOTICE: 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. NOTICE: 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. For additional information, refer to Air Bag Systems.
NOTE: Use a steering wheel holding device (such as Hunter(R) 28-75-1 or equivalent).
Using a suitable holding device, hold the steering wheel in the straight-ahead position.
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 (133 lb-in).
4. Remove and discard the lower steering column shaft-to-steering gear bolt.
- To install, tighten the new bolt to 48 Nm (35 lb-ft).
5. Disconnect the lower steering column shaft from the steering gear.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Page 5643
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. Remove and discard the 2 tie-rod end nuts.
- To install, tighten the new nuts to 103 Nm (76 lb-ft).
10. NOTICE: Use care when installing the C-Frame and Screw or damage to the tie-rod end boot
may occur.
Using the C-Frame and Screw, 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. NOTICE: 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 new lower arm forward bolt, tighten to 400 Nm (296 lb-ft).
- To install the new 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 the new nut 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.
17. NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Page 5644
- Install 2 new O-ring seals and new flag nuts.
- Fill the power steering system.
- Check and, if necessary, set the front toe.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal and Installation
1. NOTICE: 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. For additional information, refer to Air Bag Systems.
NOTE: Use a steering wheel holding device (such as Hunter(R) 28-75-1 or equivalent).
Using a suitable holding device, hold the steering wheel in the straight-ahead position.
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 the new bolt to 30 Nm (22 lb-ft).
3. Remove the 3 upper steering column shaft dash seal bolts.
- To install, tighten to 12 Nm (106 lb-in).
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 the new bolt 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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and
Repair > Steering Column Shaft - Upper > Page 5649
Steering Shaft: Service and Repair Steering Column Shaft - Lower
Steering Column Shaft - Lower
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. NOTICE: 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. For additional information, refer to Air Bag Systems.
NOTE: Use a steering wheel holding device (such as Hunter(R) 28-75-1 or equivalent).
Using a suitable holding device, hold the steering wheel in the straight-ahead position.
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 the new bolt 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 the new bolt 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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations >
Page 5653
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations >
Page 5654
Steering Wheel: Service and Repair
Steering Wheel
Removal and Installation
1. Place the steering wheel in the straight-ahead position and turn the ignition switch to the OFF
position.
2. Remove the driver air bag module. For additional information, refer to Air Bag Systems.
3. Disconnect the steering wheel switches electrical connector.
4. Remove the steering wheel bolt and the steering wheel.
- Discard the bolt.
- To install, tighten the new bolt to 40 Nm (30 lb-ft).
5. NOTICE: Do not allow the clockspring to turn from its removal position or damage to the
clockspring may occur.
Tape the clockspring center rotor to the outer housing to keep it from rotating.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair >
Page 5658
Removal
NOTICE: 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.
NOTICE: The inner ball joint grease is not compatible with water and foreign material trapped in the
grease will degrade the life of the joint.
NOTICE: 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.
4. NOTICE: Use care when installing the C-Frame and Screw or damage to the tie-rod end boot
may occur.
Using the C-Frame and Screw, separate the tie-rod end from the wheel knuckle.
5. NOTE: Count the number of turns required to remove the tie-rod end for reference during
installation.
Remove the tie-rod end.
6. Remove the tie-rod end jam nut.
7. NOTE: A new outer bellows boot clamp must be installed.
Using the Boot Clamp Pliers, remove and discard the outer bellows boot clamp.
8. NOTE: A 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. NOTICE: Place the steering gear at the center position. Use an appropriate-sized crowfoot
wrench 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.
While holding the steering gear rack, use an appropriate-sized crowfoot wrench to remove the
inner tie rod.
11. NOTICE: 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. NOTICE: Place the steering gear at the center position. Use an appropriate-sized crowfoot
wrench on the flat of the rack gear to resist
rotation and to prevent damage during the installation of the inner tie rod.
NOTE: An assistant may be needed for installation of the RH inner tie rod.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair >
Page 5659
Using an appropriate-sized crowfoot wrench, install the inner tie rod.
- Tighten to 100 Nm (74 lb-ft).
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 Boot Clamp Pliers, 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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front Suspension - rear wheel drive (RWD)
Control Arm: Service and Repair Front Suspension - rear wheel drive (RWD)
Lower Arm
Lower Arm
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front Suspension - rear wheel drive (RWD) > Page 5668
Removal
NOTICE: 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.
NOTICE: Orientation of the suspension fasteners is important. Make sure the fasteners are
installed in the same direction as 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 lower ball joint nut.
4. NOTICE: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
NOTICE: Do not damage the ball joint boot while installing the 2-Jaw Puller.
Using the 2-Jaw Puller, 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front Suspension - rear wheel drive (RWD) > Page 5669
- Discard the nut and bolt.
Installation
NOTICE: 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 new lower arm rearward bolt and nut.
2. NOTE: Do not tighten the bolt at this time.
Install the new lower arm forward bolt and nut.
3. NOTE: Do not tighten the bolt at this time.
Install the new shock absorber lower bolt and flag nut.
4. Position the stabilizer bar link and install the new nut.
- Tighten the nut to 35 Nm (26 lb-ft).
5. Connect the lower ball joint to the wheel knuckle and install the new 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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front Suspension - rear wheel drive (RWD) > Page 5670
Removal
NOTICE: 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. NOTICE: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
NOTICE: Do not damage the ball joint boot while installing the C-Frame and Screw.
Using the C-Frame and Screw, separate the upper ball joint from the wheel knuckle.
6. Using a plastic tie strap, support the suspension at the wheel knuckle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front Suspension - rear wheel drive (RWD) > Page 5671
7. Remove and discard the 2 upper arm bolts and flag nuts and remove the upper arm.
Installation
NOTICE: 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 new 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 new 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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front Suspension - rear wheel drive (RWD) > Page 5672
Control Arm: Service and Repair Rear Suspension
Lower Arm
Lower Arm
Removal
NOTICE: 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.
NOTICE: 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).
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front Suspension - rear wheel drive (RWD) > Page 5673
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.
Upper Arm
Upper Arm
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front Suspension - rear wheel drive (RWD) > Page 5674
Removal
NOTICE: 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.
NOTICE: 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).
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. NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Specifications
Cross-Member: Specifications
Torque Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 a hoist. 2. Remove the 4 transfer case skid plate
bolts and remove the transfer case skid plate.
- To install, tighten to 15 Nm (133 lb-in).
3. NOTE: Explorer/Mountaineer shown, Explorer Sport Trac similar.
Remove the heat shield bolt from the RH heat shield.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service
and Repair > Transmission Support Crossmember > Page 5680
- To install, tighten to 18 Nm (159 lb-in).
4. Remove the heat shield bolt from the LH heat shield.
- To install, tighten to 18 Nm (159 lb-in).
5. Support the transmission with a suitable jack. 6. Remove the 2 transmission mount nuts.
- To install, tighten to 90 Nm (66 lb-ft).
7. Remove the 6 transmission crossmember lower bolts.
- To install, tighten to 80 Nm (59 lb-ft).
8. NOTE: Tighten the nut side of the joint.
Remove the 2 upper nuts and 2 bolts from the transmission crossmember.
- To install, tighten to 143 Nm (105 lb-ft).
9. Remove the transmission crossmember.
10. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service
and Repair > Transmission Support Crossmember > Page 5681
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. For additional information, Vehicle Jacking
and Lifting. 2. Remove the 4 crossmember bolts. 3. Remove the 4 crossmember nuts.
- To install, tighten to 103 Nm (76 lb-ft).
4. Remove the 1B crossmember. 5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Wheel Knuckle
Removal and Installation
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 5685
NOTICE: 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. NOTICE: 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 the new bolts 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-in).
7. Remove and discard the tie-rod end nut.
- To install, tighten the new nut to 103 Nm (76 lb-ft).
8. NOTICE: Do not use a hammer to separate the tie rod from the wheel knuckle or damage to the
wheel knuckle can result.
NOTICE: Do not damage the tie-rod boot while installing the C-Frame and Screw.
Using the C-Frame and Screw, separate the tie-rod end from the wheel knuckle.
9. Remove and discard the lower ball joint nut.
- To install, tighten the new nut to 150 Nm (111 lb-ft).
10. NOTICE: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
NOTICE: Do not damage the ball joint boot while installing the 2-Jaw Puller.
Using the 2-Jaw Puller, separate the lower ball joint from the wheel knuckle.
11. Remove and discard the upper ball joint nut.
- To install, tighten the new nut to 55 Nm (41 lb-ft).
12. NOTICE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 5686
NOTICE: Do not damage the ball joint boot while installing the C-Frame and Screw.
Using the C-Frame and Screw, separate the upper ball joint and remove the wheel knuckle.
13. To install, reverse the removal procedure.
- Check and, if necessary, align the front end.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and
Repair
Rear Knuckle: Service and Repair
Wheel Knuckle
Removal
NOTICE: 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and
Repair > Page 5690
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.
NOTICE: 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. NOTICE: 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.
NOTE: Do not discard the halfshaft nut at this time.
Remove the halfshaft nut.
4. Remove the parking brake shoes.
5. NOTICE: 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.
Using the Front Wheel Hub Remover, 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. For
additional information, refer to Wheel Bearing and Wheel
Hub See: Wheel Bearing/Service and Repair/Rear Suspension.
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 the nut to 275 Nm (203 lb-ft).
3. NOTICE: The upper arm outboard bolt must be installed with the bolt head toward the front of
the vehicle or wheel damage may occur.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and
Repair > Page 5691
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-in).
8. NOTICE: Do not tighten the rear halfshaft nut with the vehicle on the ground. The nut must be
tightened to specification before the
vehicle is lowered to the ground. Wheel bearing damage will occur if the wheel bearing is loaded
with the weight of the vehicle applied.
NOTE: Apply the brake to keep the halfshaft from rotating.
Position the halfshaft in the hub and use the previously removed halfshaft nut to seat the halfshaft.
- Tighten to 275 Nm (203 lb-ft).
- Remove and discard the nut.
9. NOTICE: Install and tighten the new halfshaft nut to specification within 5 minutes of starting it
on the threads. Always install a new
halfshaft nut after loosening or when not tightening within the specified time or damage to the
components may occur.
Install a new halfshaft nut.
- Tighten to 275 Nm (203 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal
NOTICE: 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.
NOTICE: 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).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component
Information > Service and Repair > Page 5695
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).
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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Locations
Steering Angle Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Locations > Page 5700
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Locations > Page 5701
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD)
Stabilizer Link: Service and Repair Front Suspension - Rear Wheel Drive (RWD)
Stabilizer Bar and Link
Removal and Installation
NOTICE: 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.
NOTICE: Orientation of the suspension fasteners is important. Make sure the fasteners are
installed in the same direction as when removed or incorrect clamp load and damage to
components may occur.
1. Remove the wheel and tire.
2. Remove and discard the 2 stabilizer bar nuts and grommets.
- To install, tighten the new nuts 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.
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 the new bolts to 55 Nm (41 lb-ft) at curb height.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5707
6. NOTICE: The LH and RH side stabilizer bar bushings are different and are not interchangeable.
Make sure the bushings are installed on
the correct side or damage to the bushings will occur.
NOTE: When installing the LH side sway bar bushings onto the sway bar, match the groove in the
bushing to the upset on the sway bar.
NOTE: Inspect the stabilizer bar bushings for wear or damage. Install new bushings as necessary.
NOTE: Tighten LH side first.
Remove the 2 stabilizer bar bushings.
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5708
Stabilizer Link: Service and Repair Rear Suspension
Stabilizer Bar and Link - Explorer, Mountaineer
Removal
NOTICE: 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.
NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5709
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.
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. NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5710
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.
6. Install the 4 new 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. NOTICE: 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 new upper arm outboard bolts and the 2 new 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 (V6-4.0L (2009))
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 Suspension - Rear Wheel Drive (RWD)
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.
NOTICE: 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.
NOTICE: Orientation of the suspension fasteners is important. Make sure the fasteners are
installed in the same direction as 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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 5715
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. NOTICE: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
NOTICE: Do not damage the ball joint boot while installing the C-Frame and Screw.
Using the C-Frame and Screw, separate the upper ball joint from the wheel knuckle.
9. While lowering the suspension, remove the shock and spring assembly.
Installation
NOTICE: 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 new upper ball joint nut.
- Tighten to 55 Nm (41 lb-ft).
3. NOTE: Do not tighten the bolt at this time.
Install the new 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. Position the stabilizer bar link and install the new nut.
- Tighten to 35 Nm (26 lb-ft).
6. Tighten the shock absorber lower bolt to 250 Nm (258 lb-ft).
7. Install the 3 new shock absorber upper mount nuts.
- Tighten to 30 Nm (22 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 5716
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
Removal
NOTICE: 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 lower arm. For additional information, refer to Lower Arm See: Control Arm/Service
and Repair/Rear Suspension/Lower Arm.
2. Remove and discard the 3 shock absorber upper mount nuts and remove the shock absorber
and spring assembly.
- To install, tighten the new nuts 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 See: Suspension Strut / Shock Absorber/Service and Repair/Overhaul/Rear Suspension.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 5717
Suspension Spring ( Coil / Leaf ): Overhaul
Front Suspension - Rear Wheel Drive (RWD)
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.
NOTICE: 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 shock absorber and spring assembly. For additional information, refer to Shock
Absorber and Spring Assembly.
2. Using a suitable spring compressor, compress the spring until the tension is released from the
shock absorber.
3. NOTICE: When installing the shock rod nut, make sure the shock rod and bushing are centered
in the upper mount before tightening the
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 5718
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 the new nut 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. NOTICE: Make sure that the upper shock mount stud, shock rod and shock lower bushing are
aligned before tightening shock absorber
rod nut or damage to the bushing may occur.
To assemble, reverse the disassembly procedure.
Rear Suspension
Shock Absorber and Spring Assembly
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 5719
Disassembly and Assembly
1. Remove the shock absorber and spring assembly. For additional information, refer to Shock
Absorber and Spring Assembly See: Suspension Strut
/ Shock Absorber/Service and Repair/Removal and Replacement/Rear Suspension.
2. Using a suitable spring compressor, compress the spring until the tension is released from the
shock absorber.
3. NOTICE: 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 hex-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 the new nut to 65 Nm (48 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 5720
4. Remove the shock absorber.
5. Remove the shock absorber upper mount.
6. Remove the upper mount bushing.
7. Carefully release the spring compressor and remove the coil spring.
8. NOTE: Make sure the upper shock mount stud, shock rod and shock lower bushing are aligned
before tightening the shock rod nut.
To assemble, reverse the disassembly procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Rear Suspension
Shock Absorber and Spring Assembly
Removal
NOTICE: 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 lower arm. For additional information, refer to Lower Arm See: Control Arm/Service
and Repair/Rear Suspension/Lower Arm.
2. Remove and discard the 3 shock absorber upper mount nuts and remove the shock absorber
and spring assembly.
- To install, tighten the new nuts 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 See: Overhaul/Rear Suspension.
4. To install, reverse the removal procedure.
Front Suspension - Rear Wheel Drive (RWD)
Shock Absorber and Spring Assembly
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 5725
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.
NOTICE: 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.
NOTICE: Orientation of the suspension fasteners is important. Make sure the fasteners are
installed in the same direction as 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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 5726
6. Remove and discard the shock absorber lower bolt and flag nut.
7. Remove and discard the upper ball joint nut.
8. NOTICE: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
NOTICE: Do not damage the ball joint boot while installing the C-Frame and Screw.
Using the C-Frame and Screw, separate the upper ball joint from the wheel knuckle.
9. While lowering the suspension, remove the shock and spring assembly.
Installation
NOTICE: 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 new upper ball joint nut.
- Tighten to 55 Nm (41 lb-ft).
3. NOTE: Do not tighten the bolt at this time.
Install the new 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. Position the stabilizer bar link and install the new nut.
- Tighten to 35 Nm (26 lb-ft).
6. Tighten the shock absorber lower bolt to 250 Nm (258 lb-ft).
7. Install the 3 new 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 5727
Suspension Strut / Shock Absorber: Overhaul
Front Suspension - Rear Wheel Drive (RWD)
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.
NOTICE: 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 shock absorber and spring assembly. For additional information, refer to Shock
Absorber and Spring Assembly.
2. Using a suitable spring compressor, compress the spring until the tension is released from the
shock absorber.
3. NOTICE: When installing the shock rod nut, make sure the shock rod and bushing are centered
in the upper mount before tightening the
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 5728
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 the new nut 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. NOTICE: Make sure that the upper shock mount stud, shock rod and shock lower bushing are
aligned before tightening shock absorber
rod nut or damage to the bushing may occur.
To assemble, reverse the disassembly procedure.
Rear Suspension
Shock Absorber and Spring Assembly
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 5729
Disassembly and Assembly
1. Remove the shock absorber and spring assembly. For additional information, refer to Shock
Absorber and Spring Assembly See: Removal and
Replacement/Rear Suspension.
2. Using a suitable spring compressor, compress the spring until the tension is released from the
shock absorber.
3. NOTICE: 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 hex-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 the new nut to 65 Nm (48 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 5730
4. Remove the shock absorber.
5. Remove the shock absorber upper mount.
6. Remove the upper mount bushing.
7. Carefully release the spring compressor and remove the coil spring.
8. NOTE: Make sure the upper shock mount stud, shock rod and shock lower bushing are aligned
before tightening the shock rod nut.
To assemble, reverse the disassembly procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and
Repair
Trailing Arm: Service and Repair
Trailing Arm
Removal
NOTICE: 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.
NOTICE: 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. Remove the toe link. For additional information, refer to Toe Link See: Rear Knuckle Alignment
Link/Service and Repair.
2. Remove the parking brake cable bracket bolt.
- To install, tighten to 10 Nm (89 lb-in).
3. Remove and discard the trailing arm bolt.
- To install, tighten the new bolt to 300 Nm (222 lb-ft) at curb height.
4. Remove the 3 wheel knuckle bolts and the trailing arm.
- Discard the bolts.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and
Repair > Page 5734
- To install, tighten the new bolts to 275 Nm (203 lb-ft).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front Suspension
Wheel Bearing: Service and Repair Front Suspension
Wheel Bearing and Wheel Hub
Removal and Installation
NOTICE: 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. NOTICE: 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 the new bolts 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 (159 lb-in).
5. Remove the 3 bolts and the wheel bearing and wheel hub.
- Discard the bolts.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front Suspension > Page 5739
- To install, tighten the new bolts to 122 Nm (90 lb-ft).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front Suspension > Page 5740
Wheel Bearing: Service and Repair Rear Suspension
Wheel Bearing and Wheel Hub
Removal and Installation
NOTICE: 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. For additional information, refer to Wheel Knuckle See: Rear
Knuckle/Service and Repair.
2. Remove the 3 brake disc shield bolts.
- To install, tighten to 8 Nm (71 lb-in).
3. Using the Bearing Puller and a suitable press, remove the wheel hub.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front Suspension > Page 5741
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. For additional information, refer to Wheel Knuckle See: Rear
Knuckle/Service and Repair.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Front Drive Halfshaft nut.......................................................................................................................
........................................................................250 Nm (184 lb-ft)
Rear Drive Halfshaft nut.......................................................................................................................
........................................................................275 Nm (203 lb-ft)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
WARNING: 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.
WARNING: 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.
WARNING: 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.
WARNING: 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.
NOTICE: 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.
NOTICE: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on
lift without first checking for possible interference.
NOTICE: 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.
NOTICE: 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
Lifting Points
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Description and Operation > Page 5750
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 See: Tire Monitoring System/Testing
and Inspection/Programming and Relearning.
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire
Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and
appliance operation, cellular telephones, remote transmitters, power inverters and portable
entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to
activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not
respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate
the same sensor again.
NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not
recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and
the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire
procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for
front and rear tires, tire rotation will not affect the system.
1. Turn the ignition switch to the OFF position, then press and release the brake pedal.
2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
3. Press and release the brake pedal.
4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
- The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully. If equipped, the message center will display TRAIN LF TIRE.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in
place 180 degrees from the valve stem.
Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from
the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The
horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5756
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall opposite (180 degrees) from the
valve stem and press and release the test button to train the RF tire pressure sensor.
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 identifiers 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 carry out
the SJB On-Demand Self Test.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5757
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 Tire Pressure Monitor 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 Tire Pressure Monitor 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. See: Tire Monitoring System/Testing and Inspection/Symptom
Related Diagnostic Procedures
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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. NOTICE: 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. For additional information, refer to Wheel and Tire See: Service
and Repair/Overhaul.
2. NOTICE: 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.
3. NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5760
4. Remove the sensor.
Assembly
1. NOTICE: 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.
3. NOTICE: 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. For additional information, refer to Wheel and Tire See: Service and
Repair/Overhaul.
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 See: Tire Monitoring System/Testing and Inspection/Monitors,
Trips, Drive Cycles and Readiness Codes.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5761
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
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 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 See: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5762
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 in) 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. NOTICE: 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.
Using wheel and tire cleaner, clean the area where the sensor and cradle are to be installed.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5763
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. NOTICE: 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 in) away from the sensor and tighten the worm gear.
- Tighten to 3 Nm (27 lb-in).
6. NOTICE: 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. For additional information, refer to Wheel and Tire. See: Service and
Repair/Overhaul
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. See: Tire Monitoring System/Testing and Inspection/Monitors,
Trips, Drive Cycles and Readiness Codes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 See: Testing and
Inspection/Programming and Relearning.
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire
Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and
appliance operation, cellular telephones, remote transmitters, power inverters and portable
entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to
activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not
respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate
the same sensor again.
NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not
recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and
the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire
procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for
front and rear tires, tire rotation will not affect the system.
1. Turn the ignition switch to the OFF position, then press and release the brake pedal.
2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
3. Press and release the brake pedal.
4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
- The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully. If equipped, the message center will display TRAIN LF TIRE.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in
place 180 degrees from the valve stem.
Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from
the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The
horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
5769
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall opposite (180 degrees) from the
valve stem and press and release the test button to train the RF tire pressure sensor.
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 identifiers 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 carry out
the SJB On-Demand Self Test.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
5770
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 Tire Pressure Monitor 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 Tire Pressure Monitor 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. See: Testing and Inspection/Symptom Related Diagnostic
Procedures
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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. NOTICE: 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. For additional information, refer to Wheel and Tire See: Service
and Repair/Overhaul.
2. NOTICE: 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.
3. NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5773
4. Remove the sensor.
Assembly
1. NOTICE: 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.
3. NOTICE: 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. For additional information, refer to Wheel and Tire See: Service and
Repair/Overhaul.
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 See: Testing and Inspection/Monitors, Trips, Drive Cycles and
Readiness Codes.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5774
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
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 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 See: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5775
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 in) 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. NOTICE: 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.
Using wheel and tire cleaner, clean the area where the sensor and cradle are to be installed.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5776
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. NOTICE: 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 in) away from the sensor and tighten the worm gear.
- Tighten to 3 Nm (27 lb-in).
6. NOTICE: 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. For additional information, refer to Wheel and Tire. See: Service and
Repair/Overhaul
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. See: Testing and Inspection/Monitors, Trips, Drive Cycles and
Readiness Codes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 5785
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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat
Cracking
Wheels: Customer Interest Wheels - 17 Inch Polished Wheel Clearcoat Cracking
TSB 09-14-1
07/27/09
17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and
equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks
in the clear coat that look like spider webs.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Please review the illustrations of an affected wheel. (Figures 1 and 2)
2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04
for wheel removal and installation procedures
including tire pressure monitoring system (TPMS) sensor.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5790
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
091401A 2006-2010 Explorer, 0.6 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer
TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091401B 2006-2010 Explorer, 0.8 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401C 2006-2010 Explorer, 1.1 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To
Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401D 2006-2010 Explorer, 1.3 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 91
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 5796
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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel
Clearcoat Cracking
Wheels: All Technical Service Bulletins Wheels - 17 Inch Polished Wheel Clearcoat Cracking
TSB 09-14-1
07/27/09
17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and
equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks
in the clear coat that look like spider webs.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Please review the illustrations of an affected wheel. (Figures 1 and 2)
2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04
for wheel removal and installation procedures
including tire pressure monitoring system (TPMS) sensor.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5801
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
091401A 2006-2010 Explorer, 0.6 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer
TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091401B 2006-2010 Explorer, 0.8 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401C 2006-2010 Explorer, 1.1 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To
Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401D 2006-2010 Explorer, 1.3 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 91
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front Suspension
Wheel Bearing: Service and Repair Front Suspension
Wheel Bearing and Wheel Hub
Removal and Installation
NOTICE: 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. NOTICE: 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 the new bolts 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 (159 lb-in).
5. Remove the 3 bolts and the wheel bearing and wheel hub.
- Discard the bolts.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front Suspension > Page 5806
- To install, tighten the new bolts to 122 Nm (90 lb-ft).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front Suspension > Page 5807
Wheel Bearing: Service and Repair Rear Suspension
Wheel Bearing and Wheel Hub
Removal and Installation
NOTICE: 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. For additional information, refer to Wheel Knuckle See:
Suspension/Rear Knuckle/Service and Repair.
2. Remove the 3 brake disc shield bolts.
- To install, tighten to 8 Nm (71 lb-in).
3. Using the Bearing Puller and a suitable press, remove the wheel hub.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front Suspension > Page 5808
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. For additional information, refer to Wheel Knuckle See:
Suspension/Rear Knuckle/Service and Repair.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 5817
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 5823
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 (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information
> Specifications
Axle Nut: Specifications
Front Drive Halfshaft nut.......................................................................................................................
........................................................................250 Nm (184 lb-ft)
Rear Drive Halfshaft nut.......................................................................................................................
........................................................................275 Nm (203 lb-ft)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications
Wheel Fastener: Specifications
NOTICE: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout,
which will speed up the development of brake roughness, shudder and vibration.
Tighten the wheel nuts, using the pattern indicated,
to..............................................................................................................................135 Nm (100
lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front Suspension - Rear Wheel Drive (RWD)
Wheel Fastener: Service and Repair Front Suspension - Rear Wheel Drive (RWD)
Wheel Studs
Removal
1. Remove the wheel and tire.
2. NOTICE: 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 the new bolts to 165 Nm (122 lb-ft).
3. Remove the brake disc.
4. Using the C-Frame and Screw, remove the wheel stud.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5833
Installation
1. NOTICE: 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.
NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud
serrations. Use enough washers (approximately 4) to allow the wheel stud to fully seat against the
hub flange.
Install approximately 4 washers and a new wheel nut on the wheel stud and tighten the nut until the
stud seats against the flange. -
Discard the wheel nut and washers.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5834
Wheel Fastener: Service and Repair Rear Suspension
Wheel Studs
Removal
NOTICE: 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.
NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5835
2. NOTICE: 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.
NOTICE: 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 C-Frame and Screw, press the wheel stud until it makes contact with the edge of the
wheel knuckle.
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. NOTICE: 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.
NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud
serrations. Use enough washers (approximately 4) to allow the wheel stud to fully seat against the
hub flange.
Place approximately 4 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. NOTICE: A plug must be installed in place of the knockout to prevent contamination to the
parking brake shoe assemblies.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5836
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 (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and
Repair
Accumulator HVAC: Service and Repair
Suction Accumulator
Removal and Installation
NOTICE: 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 (97 lb-in).
5. Remove the PCM bracket bolt.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and
Repair > Page 5841
6. Remove the PCM bracket nut and the PCM bracket.
7. Remove the suction accumulator stud.
- To install, tighten to 11 Nm (97 lb-in).
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 (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > LH Temperature Blend Door Actuator
Air Door Actuator / Motor: Locations LH Temperature Blend Door Actuator
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > LH Temperature Blend Door Actuator > Page 5847
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > LH Temperature Blend Door Actuator > Page 5848
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > LH Temperature Blend Door Actuator > Page 5849
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > LH Temperature Blend Door Actuator > Page 5850
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Auxiliary Temperature Blend Door Actuator
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Auxiliary Temperature Blend Door Actuator > Page 5853
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Auxiliary Temperature Blend Door Actuator > Page 5854
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Auxiliary Temperature Blend Door Actuator > Page 5855
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Temperature Blend Door Actuator - LH
Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator - LH
Temperature Blend Door Actuator - LH
Removal and Installation
1. Remove the LH floor console finish panel.
2. Position the in-vehicle temperature sensor aspirator hose away from the LH temperature blend
door actuator.
3. Remove the 3 LH temperature blend door actuator screws.
4. Disconnect the LH temperature blend door actuator electrical connector.
5. Remove the LH temperature blend door actuator.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5858
Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator - RH, EATC
Temperature Blend Door Actuator - RH, EATC
Removal and Installation
1. Remove the RH floor console finish panel.
2. Lower the glove compartment.
3. Disconnect the RH temperature blend door actuator electrical connector.
4. Remove the 3 RH temperature blend door actuator screws.
5. Remove the RH temperature blend door actuator.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5859
Air Door Actuator / Motor: Service and Repair Auxiliary Mode Door Actuator
Auxiliary Mode Door Actuator
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the LH quarter trim panel.
3. Remove the 2 auxiliary line floorpan bracket nuts.
- To install, tighten to 8 Nm (71 lb-in).
4. Remove the 2 auxiliary heater core and evaporator core housing bolts.
- 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5860
9. Remove the auxiliary mode door actuator.
10. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5861
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
retaining arm.
Rotate the defrost door vacuum control motor until it clears the retaining arm and remove the
defrost door vacuum control motor.
8. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5862
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.
Temperature Blend Door Actuator - RH, EATC
Temperature Blend Door Actuator - RH, EATC
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5863
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 (V6-4.0L (2009))
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 5864
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).
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5865
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
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 (V6-4.0L (2009))
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 5866
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5867
10. To install, reverse the removal procedure.
Vacuum Control Motor - Panel Door
Vacuum Control Motor - Panel Door
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5868
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.
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.
- 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5869
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 (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair
Air Duct: Service and Repair
Air Inlet Duct
Removal and Installation
1. Remove the heater core and evaporator core housing.
2. Remove the air inlet duct.
1. Remove the support bracket screw.
2. Disconnect the air inlet door vacuum control motor vacuum connector.
3. Remove the 3 air inlet duct screws.
4. Remove the air inlet duct.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 5876
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 5877
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 5878
Ambient Temperature Sensor / Switch HVAC: Testing and Inspection
Climate Control System
Component Tests
Temperature Sensor - Ambient
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information
> Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information
> Locations > Page 5883
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Auxiliary Blower Motor Relay
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Auxiliary Blower Motor Relay > Page 5888
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Auxiliary Blower Motor Relay > Page 5889
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams >
Blower Motor Relay 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams >
Blower Motor Relay 2 > Page 5892
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Auxiliary Blower Motor Relay
Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Auxiliary Blower Motor Relay > Page 5895
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Auxiliary Blower Motor Relay > Page 5896
Blower Motor Relay: Testing and Inspection Blower Motor Relay 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Auxiliary Blower Motor Relay > Page 5897
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Auxiliary Blower Motor Relay > Page 5898
Blower Motor Relay: Testing and Inspection Blower Motor Relay 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Auxiliary Blower Motor Relay > Page 5899
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations >
Front Blower Motor Resistor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations >
Front Blower Motor Resistor > Page 5904
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams >
Front Blower Motor Resistor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams >
Front Blower Motor Resistor > Page 5907
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and
Inspection > Resistor - Blower Motor, Front
Blower Motor Resistor: Testing and Inspection Resistor - Blower Motor, Front
Climate Control System
Component Tests
Resistor - Blower Motor, Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and
Inspection > Resistor - Blower Motor, Front > Page 5910
Blower Motor Resistor: Testing and Inspection Resistor - Blower Motor, Auxiliary
Climate Control System
Component Tests
Resistor - Blower Motor, Auxiliary
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and
Repair > Blower Motor Resistor > Page 5913
Blower Motor Resistor: Service and Repair Auxiliary Blower Motor Resistor
Auxiliary Blower Motor Resistor
Removal and Installation
1. Remove the switch bezel.
2. Disconnect the power lock switch electrical connector.
3. Remove the access panel.
4. Disconnect the auxiliary blower motor resistor electrical connector.
5. Remove the 2 auxiliary blower motor resistor screws.
6. Remove the auxiliary blower motor resistor.
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations >
Page 5917
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations >
Page 5918
Blower Motor Switch: Service and Repair
Blower Motor Speed Control
Removal and Installation
1. Remove the blower motor speed control screw.
2. Remove the blower motor speed control.
3. Disconnect the blower motor speed control electrical connector.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair
Cabin Air Filter: Service and Repair
The air distribution system of this vehicle cannot be equipped with a cabin air filter.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations > Page 5925
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations > Page 5926
Cabin Temperature Sensor / Switch: Testing and Inspection
Climate Control System
Component Tests
Temperature Sensor - In-Vehicle
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Service and Repair > Ambient Air Temperature Sensor
Cabin Temperature Sensor / Switch: Service and Repair Ambient Air Temperature Sensor
Ambient Air Temperature Sensor
Removal and Installation
Mountaineer
1. Remove the radiator grille.
2. Remove the pin-type retainers and position the air deflector forward.
3. Remove the 2 air deflector pin-type retainers and detach the air deflector from the 2 locator pins
on the radiator support.
All vehicles
4. Detach the ambient air temperature sensor electrical connector.
5. Remove the ambient air temperature sensor.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Service and Repair > Ambient Air Temperature Sensor > Page 5929
Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor
In-Vehicle Temperature Sensor
Removal and Installation
1. Remove the instrument cluster finish panel.
2. Remove the in-vehicle temperature sensor.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications
Compressor Clutch: Specifications
A/C Compressor Magnetic Clutch Air gap clearance...........................................................................
..........................................................................................0.35-0.65 mm (0.014-0.026 in)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 5934
Compressor Clutch: Adjustments
Air Conditioning (A/C) Clutch Air Gap Adjustment
1. Check the A/C clutch air gap at 3 equally spaced places between the clutch plate and the A/C
clutch pulley.
2. Remove the clutch plate. Add or remove spacers between the clutch plate hub and the
compressor shaft until the clearance is within specification.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 5938
Compressor Clutch Coil: Service and Repair
Clutch and Clutch Field Coil
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 5939
Removal
All vehicles
1. Remove the A/C compressor. For additional information, refer to Air Conditioning (A/C)
Compressor - 4.0L SOHC See: Service and Repair or
Air Conditioning (A/C) Compressor - 4.6L See: Service and Repair.
2. Remove the A/C clutch disc and hub bolt.
1. Hold the A/C clutch disc and hub with the Compressor Clutch Disc and Hub Holding Fixture.
2. Remove the A/C clutch disc and hub bolt.
3. Remove the A/C clutch disc and hub.
4. Remove the A/C compressor pulley snap ring.
5. Remove the A/C compressor pulley.
1. Install the Compressor Pulley Remover
2. Remove the A/C compressor pulley.
FS18 compressors only
6. NOTICE: 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 Field Coil Remover.
2. Install the Compressor Pulley Remover.
3. Remove the A/C clutch field coil.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 5940
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. NOTICE: 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 Field Coil Replacer on the A/C clutch field coil.
3. Place the Coil Replacer 412-065 on the Field Coil Replacer 412-078.
4. Use the Compressor Pulley Remover 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 5941
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 Compressor Clutch Disc and Hub Holding Fixture.
2. Install the A/C clutch disc and hub bolt.
- Tighten to 14 Nm (124 lb-in).
12. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers.
13. Install the A/C compressor. For additional information, refer to Air Conditioning (A/C)
Compressor - 4.0L SOHC See: Service and Repair or Air
Conditioning (A/C) Compressor - 4.6L See: Service and Repair.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 5945
Compressor Clutch Relay: Description and Operation
Engine Control Components
Air Conditioning (A/C) Clutch Relay (A/CCR)
Note: The PCM parameter identifiers (PIDs) wide open throttle air conditioning cutoff (WAC) and
wide open throttle air conditioning cutoff fault (WAC_F) 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 and the engine conditions are OK (coolant temperature, engine RPM, throttle position),
the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to the A/CCR.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 5946
Compressor Clutch Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 5947
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation
Condenser HVAC: Description and Operation
Air Conditioning
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 (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation > Page 5951
Condenser HVAC: Service and Repair
Condenser Core
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation > Page 5952
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 (106 lb-in).
9. Remove the upper radiator air deflector.
10. Remove the 2 condenser core bolts.
- To install, tighten to 12 Nm (106 lb-in).
11. Remove the condenser core.
12. Remove the 2 condenser air deflectors.
13. To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
14. Evacuate, leak test and charge the refrigerant system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Climate Control Assembly
Control Assembly: Diagrams Climate Control Assembly
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Climate Control Assembly > Page 5957
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Climate Control Assembly > Page 5958
Control Assembly: Diagrams Auxiliary Climate Control Assembly, Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Climate Control Assembly > Page 5959
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Climate Control Assembly > Page 5962
Control Assembly: Service and Repair Auxiliary Climate Control Assembly
Auxiliary Climate Control Assembly
Removal and Installation
1. Remove the overhead console.
2. Remove the 2 screws.
3. Remove the bezel.
4. Remove the auxiliary climate control assembly.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Climate Control Assembly > Page 5963
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 (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations >
Page 5967
Control Module HVAC: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations >
Page 5968
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation
Evaporator Core: Description and Operation
Air Conditioning
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 (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation > Page 5972
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. For additional information, refer to Heater Core See: Heater
Core/Service and Repair/Heater Core.
2. Remove the 5 outer evaporator core cover screws.
3. Remove the 6 inner evaporator core cover screws.
4. Separate the evaporator core cover from the heater core and evaporator core housing.
- Discard the rope seal.
5. Remove the evaporator core.
6. To install, reverse the removal procedure.
- Apply a bead of RTV sealant around the entire evaporator core housing groove joint in place of
the rope seal.
- Tighten the evaporator core cover screws in a diagonal pattern to distribute the RTV sealant
evenly.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various
A/T Solenoid DTC's
Evaporator Drain Tube: Customer Interest A/T Controls - MIL ON/Various A/T Solenoid DTC's
TSB 09-22-15
11/16/09
5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION
FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR
BEFORE 8/12/2009
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or
before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with
diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related
DTCs. This may be due to water traveling down from the A/C drain into the solenoid body
connector on the left side of the transmission.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify any transmission related symptoms or transmission related DTC's that are present.
2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be
coming from the A/C drain. (Figure 1)
3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed.
4. Cut and install patch kit over the connector. (Figure 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5981
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092215A 2006-2010 Explorer, 0.4 Hr.
Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease
Connector, Install Patch (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7G391 X2
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 09-22-15 > Nov > 09 > A/T Controls - MIL
ON/Various A/T Solenoid DTC's
Evaporator Drain Tube: All Technical Service Bulletins A/T Controls - MIL ON/Various A/T Solenoid
DTC's
TSB 09-22-15
11/16/09
5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION
FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR
BEFORE 8/12/2009
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or
before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with
diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related
DTCs. This may be due to water traveling down from the A/C drain into the solenoid body
connector on the left side of the transmission.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify any transmission related symptoms or transmission related DTC's that are present.
2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be
coming from the A/C drain. (Figure 1)
3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed.
4. Cut and install patch kit over the connector. (Figure 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 5987
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092215A 2006-2010 Explorer, 0.4 Hr.
Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease
Connector, Install Patch (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7G391 X2
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Description and Operation
Evaporator Temperature Sensor / Switch: Description and Operation
Engine Control Components
Air Conditioning Evaporator Temperature (ACET) Sensor
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 and improve defrost/demist
performance.
Note: These values can vary 15% due to sensor and VREF variations. Voltage values were
calculated for VREF equals 5.0 volts.
A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Description and Operation > Evaporator Core Orifice
Expansion Block/Orifice Tube: Description and Operation Evaporator Core Orifice
Air Conditioning
Evaporator Core Orifice
NOTE: A new evaporator core orifice should be installed whenever a new A/C compressor is
installed.
The evaporator core orifice is located in the condenser-to-evaporator line, and can be removed
through an access fitting. The evaporator core orifice provides a restriction to the flow of refrigerant
from the high-pressure side of the refrigerant system and separates the low-pressure and
high-pressure sides of the refrigerant system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Description and Operation > Evaporator Core Orifice > Page 5995
Expansion Block/Orifice Tube: Description and Operation A/C Pressure Transducer
Air Conditioning
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 (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair > Evaporator Core Orifice
Expansion Block/Orifice Tube: Service and Repair Evaporator Core Orifice
Evaporator Core Orifice
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 Fixed Orifice Remover/Installer. Hold the
T-handle stationary while rotating the tool body to
remove the evaporator core orifice.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair > Evaporator Core Orifice > Page 5998
5. If the evaporator core orifice is broken, screw the end of the Broken Orifice Remover 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 Fixed Orifice Remover/Installer.
2. Install a new O-ring seal and connect the evaporator core orifice access fitting.
- To install, tighten to 18 Nm (159 lb-in).
3. Lubricate the refrigerant system with the correct amount of clean PAG oil.
4. Evacuate, leak test and charge the refrigerant system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair > Evaporator Core Orifice > Page 5999
Expansion Block/Orifice Tube: Service and Repair Thermostatic Expansion Valve
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.
7. Disconnect the 2 TXV fittings and remove the TXV.
- Discard the O-ring seals.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair > Evaporator Core Orifice > Page 6000
- To install, tighten to 23 Nm (17 lb-ft).
8. To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
9. Evacuate, leak test and charge the refrigerant system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and
Repair
Heater Control Valve: Service and Repair
Heater Control Valve
Removal and Installation
Vehicles with 4.0L and oil cooler, without auxiliary climate control
1. With the vehicle in NEUTRAL, position it on a hoist.
All vehicles
2. Drain the engine coolant.
3. Disconnect the 2 inlet and outlet heater hose clamps.
4. Disconnect the heater control valve vacuum hose.
Vehicles with 4.0L and oil cooler, without auxiliary climate control
5. Remove the heater control valve bolt.
All vehicles
6. Remove the heater control valve.
7. NOTE: Lubricate the coolant hoses with plain water only if needed.
To install, reverse the removal procedure.
8. Fill the engine cooling system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection
> Heater Core
Heater Core: Testing and Inspection Heater Core
Climate Control System
Component Tests
Heater Core
1. NOTE: 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: See: Heater Core - Plugged
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection
> Heater Core > Page 6008
Heater Core: Testing and Inspection Heater Core - Plugged
Climate Control System
Component Tests
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, using a suitable temperature
measuring device, check 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection
> Heater Core > Page 6009
Heater Core: Testing and Inspection Heater Core - Pressure Test
Climate Control System
Component Tests
Heater Core - Pressure Test
Use the Pressure Test Kit 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 Pressure Test Kit 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 Pressure Test Kit 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. See: Heater Core - Bench Test
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection
> Heater Core > Page 6010
Heater Core: Testing and Inspection Heater Core - Bench Test
Climate Control System
Component Tests
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
from the Pressure Test Kit to the adapter.
4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water.
5. If a leak is observed, replace the heater core.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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. For additional information, refer to Heater
Core And Evaporator Core Housing See:
Housing Assembly HVAC/Service and Repair/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.
8. Remove the 3 heater tube cover screws.
9. Remove the heater tube cover.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Heater Core > Page 6013
10. Remove the heater tube seal.
11. Remove the 4 heater core cover screws.
12. Remove the heater core cover.
13. Remove the heater core.
14. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Heater Core > Page 6014
Heater Core: Service and Repair Auxiliary Heater Core
Auxiliary Heater Core
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Heater Core > Page 6015
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.
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 heater core and evaporator core housing bolts and auxiliary heater core
and evaporator core 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Heater Core > Page 6016
18. To install, reverse the removal procedure.
- Lubricate the coolant hoses with plain water only if needed.
19. Fill the engine cooling system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest for Heater Hose: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC P2135 Set
Heater Hose: Customer Interest A/C, Engine Controls - MIL ON/DTC P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest for Heater Hose: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC P2135 Set >
Page 6025
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Hose: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC
P2135 Set
Heater Hose: All Technical Service Bulletins A/C, Engine Controls - MIL ON/DTC P2135 Set
TSB 09-22-4
11/16/09
DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009
FORD: 2009-2010 Explorer
MERCURY: 2009-2010 Mountaineer
ISSUE Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009
and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp
(MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose.
The vehicle may also exhibit a reduction in power or hesitation.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify DTC P2135 is present.
2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS)
connector and wiring. (Figure 1)
a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.
b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.
3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.
4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise
until the hose is oriented as shown in the picture and
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Hose: > 09-22-4 > Nov > 09 > A/C, Engine Controls - MIL ON/DTC
P2135 Set > Page 6031
install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the
hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all
clamps on the other heater hose.
5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn,
repair as needed.
6. Top off engine coolant as needed.
7. Clear DTC's.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate The Heater Hose Following The Service Procedure (Do Not Use With
Any Other Labor Operations)
092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate The Heater Hose; Repair Wires At The TPS Connector Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Air Conditioning
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 (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Description and Operation > Page 6035
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 (V6-4.0L (2009))
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 - 4.0L SOHC
Removal and Installation
1. Recover the refrigerant.
2. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket.
- To install, tighten to 7 Nm (62 lb-in).
3. Remove the compressor discharge fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (133 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 compressor-to-condenser discharge line.
7. To install, reverse the removal procedure.
- Install a new gasket seal and O-ring seals.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6040
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
8. Evacuate, leak test and charge the refrigerant system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6041
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6042
- 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6043
Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Front
Auxiliary Evaporator Outlet and Inlet Line - Front
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6044
6. Remove the front auxiliary evaporator line fitting nuts and disconnect the fittings.
- Discard the O-ring seals.
- To install, tighten to 8 Nm (71 lb-in).
7. Remove the 3 auxiliary line bracket nuts.
- To install, tighten to 6 Nm (53 lb-in).
8. Remove the 3 auxiliary line bracket bolts.
- To install, tighten to 6 Nm (53 lb-in).
9. Remove the 6 auxiliary line brackets.
10. Remove the front auxiliary evaporator outlet and inlet lines.
11. To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
12. Evacuate, leak test and charge the refrigerant system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6045
Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Rear
Auxiliary Evaporator Outlet and Inlet Line - Rear
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6046
6. Remove the 2 rear auxiliary evaporator line front fitting nuts and disconnect the fittings.
- Discard the O-ring seals.
- To install, tighten to 8 Nm (71 lb-in).
7. Remove the 2 rear auxiliary evaporator line rear fitting nuts and disconnect the fittings.
- Discard the O-ring seals.
- To install, tighten to 8 Nm (71 lb-in).
8. Remove the auxiliary line bracket nut.
- To install, tighten to 6 Nm (53 lb-in).
9. Remove the 2 auxiliary line brackets.
10. Remove the rear auxiliary evaporator outlet line.
11. Remove the rear auxiliary evaporator inlet line.
- Discard the Thermostatic Expansion Valve (TXV) filter.
12. To install, reverse the removal procedure.
- Install new O-ring seals.
- Install a new TXV filter.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
13. Evacuate, leak test and charge the refrigerant system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6047
Hose/Line HVAC: Service and Repair
Compressor To Condenser Discharge Line
Compressor to Condenser Discharge Line - 4.0L SOHC
Removal and Installation
1. Recover the refrigerant.
2. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket.
- To install, tighten to 7 Nm (62 lb-in).
3. Remove the compressor discharge fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (133 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 compressor-to-condenser discharge line.
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6048
- Install a new gasket seal and O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
8. 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.
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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6049
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 (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6050
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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6051
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
Removal and Installation
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6052
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 - 4.0L SOHC
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6053
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Recover the refrigerant.
3. Remove the compressor suction fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (133 lb-in).
4. Release the brake booster vacuum hose clamp and disconnect the hose.
5. Remove the suction accumulator-to-compressor line bracket bolt at the dash panel.
- To install, tighten to 11 Nm (97 lb-in).
6. Remove the suction accumulator outlet fitting nut.
- To install, tighten to 8 Nm (71 lb-in).
7. Disconnect the auxiliary evaporator outlet line fitting (if equipped).
- Discard the O-ring seals.
8. Remove the suction accumulator-to-compressor line.
- Discard the O-ring seal.
9. To install, reverse the removal procedure.
- Install new O-ring seals and a new gasket seal.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
10. Evacuate, leak test and charge the refrigerant system.
Suction Accumulator To Evaporator Line
Suction Accumulator To Evaporator Line
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6054
Removal and Installation
All vehicles
1. Remove the suction accumulator. For additional information, refer to Suction Accumulator See:
Accumulator HVAC/Service and Repair.
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.
4. Disconnect the evaporator outlet fitting.
- Discard the O-ring seals.
Vehicles with 4.0L engine
5. Disconnect the Evaporative Emission (EVAP) return line fitting at the intake manifold.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6055
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.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
Auxiliary Heater Outlet and Inlet Line - Front
Auxiliary Heater Outlet and Inlet Line - Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6056
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.
Auxiliary Heater Outlet and Inlet Line - Rear
Auxiliary Heater Outlet and Inlet Line - Rear
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6057
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Drain the engine coolant.
3. Remove the spare tire.
4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type retainers.
5. Remove the spare tire carrier.
6. Release the 2 rear auxiliary heater line front hose clamps and disconnect the hoses.
7. Release the 2 rear auxiliary heater line rear hose clamps and disconnect the hoses.
8. Remove the 2 auxiliary line bracket nuts.
- 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line > Page 6058
12. To install, reverse the removal procedure.
13. Fill the engine cooling system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
NOTE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core And Evaporator Core Housing > Page 6063
5. Remove the heater tube bracket nut.
6. Remove the dash panel A/C line bracket nut.
- To install, tighten to 11 Nm (97 lb-in).
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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core And Evaporator Core Housing > Page 6064
17. Evacuate, leak test and charge the refrigerant system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core And Evaporator Core Housing > Page 6065
Housing Assembly HVAC: Service and Repair Plenum Chamber
Plenum Chamber
Removal and Installation
1. Remove the instrument panel.
2. Remove the Audio Control Module (ACM).
3. Remove the 3 plenum chamber screws.
4. Remove the instrument panel upper finish panel.
5. Remove the 3 defroster duct screws.
6. Remove the defroster duct.
7. Remove the plenum chamber.
8. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core And Evaporator Core Housing > Page 6066
Housing Assembly HVAC: Service and Repair Auxiliary Heater Core and Evaporator Core Housing
Auxiliary Heater Core and Evaporator Core Housing
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core And Evaporator Core Housing > Page 6067
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.
- To install, tighten to 6 Nm (53 lb-in).
11. Disconnect the auxiliary harness electrical connector.
12. Remove the auxiliary heater core and evaporator core housing.
13. To install, reverse the removal procedure.
- Clean and lubricate the coolant hoses with plain water only if needed.
- Install new O-ring seals.
- Install a new TXV filter.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
14. Fill the engine cooling system.
15. Evacuate, leak test and charge the refrigerant system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Item..............................................................................................................................R-134a
Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification...........................................
......................................................................................................................................................WS
H-M17B19-A Fill
Capacity...........................................................................................................................(0.77 kg) (27
oz) (1.7 lb) (vehicles without auxiliary systems)
Item..............................................................................................................................R-134a
Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification...........................................
......................................................................................................................................................WS
H-M17B19-A Fill
Capacity...................................................................................................................(1.25 kg) (44 oz)
(2.75 lb) (vehicles with auxiliary climate control)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 6072
Refrigerant: Fluid Type Specifications
Item..............................................................................................................................R-134a
Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification...........................................
......................................................................................................................................................WS
H-M17B19-A Fill
Capacity...........................................................................................................................(0.77 kg) (27
oz) (1.7 lb) (vehicles without auxiliary systems)
Item..............................................................................................................................R-134a
Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification...........................................
......................................................................................................................................................WS
H-M17B19-A Fill
Capacity...................................................................................................................(1.25 kg) (44 oz)
(2.75 lb) (vehicles with auxiliary climate control)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page
6073
Refrigerant: Testing and Inspection
Refrigerant Identification Testing
Refrigerant Identification
1. NOTE: A Refrigerant Blend Identifier with Printer must be used to identify gas samples taken
directly from the refrigeration system or storage
containers prior to recovering or charging the refrigerant system.
Follow the instructions included with the Refrigerant Blend Identifier with Printer to obtain the
sample for testing.
2. The Refrigerant Blend Identifier with Printer will display one of the following:
- If the purity level of R-134a is 98% or greater by weight, the green PASS LED will light. The
weight concentrations of R-134a, R-12, R-22, hydrocarbons and air will be displayed on the digital
display.
- If refrigerant R-134a does not meet the 98% purity level, the red FAIL LED will light and an alarm
will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22
and hydrocarbons will be displayed on the digital display.
- If hydrocarbon concentrations are 2% or greater by weight, the red FAIL LED will light,
"Hydrocarbon High" will be displayed on the digital display, and an alarm will sound alerting the
user of potential hazards. The weight concentrations of R-134a, R-12, R-22 and hydrocarbons will
also be displayed on the digital display.
3. The percentage of air contained in the sample will be displayed if the R-134a content is 98% or
greater. The Refrigerant Blend Identifier with
Printer eliminates the effect of air when determining the refrigerant sample content because air is
not considered a contaminant, although air can affect A/C system performance. When the
Refrigerant Blend Identifier with Printer has determined that a refrigerant source is pure (R-134a is
98% or greater by weight) and air concentration levels are 2% or greater by weight, the scan tool
will prompt the user if an air purge is desired.
4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the
refrigerant is indeed contaminated.
Contaminated Refrigerant Handling
NOTICE: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a
recovery/recycling equipment. Recovery of contaminated refrigerant will contaminate the recovered
refrigerant supply and may damage the recovery/recycling equipment.
NOTE: A new suction accumulator or receiver/drier must be installed as directed by the A/C system
flushing procedure.
1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant only.
- If this equipment is not available, contact an A/C service facility in the area with the correct
equipment to carry out this service.
2. Determine and correct the cause of the customers initial concern.
3. Flush the A/C system.
4. Dispose of the contaminated refrigerant in accordance with all federal, state and local
regulations.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air
Conditioning (A/C) System Recovery, Evacuation and Charging
Refrigerant: Service and Repair Air Conditioning (A/C) System Recovery, Evacuation and Charging
Air Conditioning (A/C) System Recovery, Evacuation and Charging
Refrigerant System Recovery
NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any
vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If
the vehicle's A/C refrigerant is contaminated, refer the customer to the service
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air
Conditioning (A/C) System Recovery, Evacuation and Charging > Page 6076
facility that carried out the last A/C service. If the customer wishes to pay the additional cost, use
the A/C recovery equipment that is designated for recovering contaminated A/C refrigerant. All
contaminated A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow
the equipment manufacturer procedures and instructions.
NOTE: Ford Motor Company recommends the use of R-134a refrigerant management equipment
that meets the requirements of the SAE J2788 standard.
NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to
carry out recovery. If a R-134a Refrigerant Management Machine is not available, refrigerant
system recovery may be accomplished using a separate recovery station.
NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in
vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is
necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly
basis to verify that no leaks are present.
1. Prior to recovering, the purity of the refrigerant must be verified. For additional information, refer
to Refrigerant Identification Testing See:
Testing and Inspection/Component Tests and General Diagnostics/Refrigerant Identification
Testing.
2. Connect a R-134a Refrigerant Management Machine to the low- and high-pressure service
gauge port valves following the operating instructions
provided by the equipment manufacturer.
3. Recover the refrigerant from the system following the operating instructions provided by the
equipment manufacturer. Note the amount of oil
removed during the refrigerant recovery (if any). Add that same amount back into the system once
repairs are complete.
4. Once the R-134a Refrigerant Management Machine has recovered the refrigerant, switch OFF
the power supply.
5. Allow the system to set for about 2 minutes, and observe the system vacuum reading. If the
vacuum is not lost, disconnect the recovery equipment.
6. If the system does lose vacuum, repeat Steps 3 through 5 until the vacuum level remains stable
for 2 minutes.
7. Carry out the required repairs.
Refrigerant System Evacuation Using a R-134a Refrigerant Management Machine
NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to
carry out recovery, evacuation and charging of the refrigerant system. If a R-134a Refrigerant
Management Machine is not available, evacuation may be accomplished using a separate Vacuum
Pump and R-134a Manifold Gauge Set.
NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in
vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is
necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly
basis to verify that no leaks are present.
1. Connect a R-134a Refrigerant Management Machine to the low- and high-pressure service
gauge port valves following the operating instructions
provided by the equipment manufacturer.
2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of
vacuum and as close to 101.1 kPa (30 in-Hg) as possible.
Continue to operate the Vacuum Pump for a minimum of 45 minutes.
3. Turn OFF the Vacuum Pump. Observe the low-pressure gauge for 5 minutes to make sure that
the system vacuum is held. If vacuum is not held for
5 minutes, leak test the system, repair the leak and evacuate the system again.
Refrigerant System Evacuation Using a R-134a Manifold Gauge Set and Vacuum Pump
NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to
carry out evacuation of the refrigerant system. If a R-134a Refrigerant Management Machine is not
available, refrigerant system evacuation may be accomplished using a separate Vacuum Pump
and R-134a Manifold Gauge Set.
NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in
vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is
necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly
basis to verify that no leaks are present.
1. Connect the R-134a Manifold Gauge Set to the low-side and high-side service gauge port
valves.
2. Connect the center (yellow) hose from the R-134a Manifold Gauge Set to the suction port on the
Vacuum Pump.
3. Open all valves on the R-134a Manifold Gauge Set and both service gauge port valves.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air
Conditioning (A/C) System Recovery, Evacuation and Charging > Page 6077
4. Turn on the Vacuum Pump and evacuate the system until the low-pressure gauge reads at least
99.4 kPa (29.5 in-Hg) of vacuum and as close to
101.1 kPa (30 in-Hg) as possible. Continue to operate the Vacuum Pump for a minimum of 45
minutes.
5. Close the high-side and low-side valves on the R-134a Manifold Gauge Set (not the service
gauge port valves) and turn OFF the Vacuum Pump.
6. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If
vacuum is not held for 5 minutes, leak test the
system, repair the leak and evacuate the system again.
Refrigerant System Charging Using a R-134a Refrigerant Management Machine
NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to
carry out charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not
available, refrigerant system charging may be accomplished using a separate Automatic
Refrigerant Charging Meter and R-134a Manifold Gauge Set.
NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may
be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all
refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks
are present.
1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional
information, refer to Refrigerant Oil Adding See:
Service and Repair/Refrigerant Oil Adding.
2. Connect a R-134a Refrigerant Management Machine to the low-side and high-side service
gauge port valves following the operating instructions
provided by the equipment manufacturer.
3. Set the refrigerant charge amount, and charge the refrigerant system following the instructions
provided by the equipment manufacturer.
Refrigerant System Charging Using a R-134a Manifold Gauge Set and Automatic Refrigerant
Charging Meter
NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to
carry out charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not
available, refrigerant system charging may be accomplished using a separate Automatic
Refrigerant Charging Meter and R-134a Manifold Gauge Set.
NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may
be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all
refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks
are present.
1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional
information, refer to Refrigerant Oil Adding See:
Service and Repair/Refrigerant Oil Adding.
2. Assemble the R-134a Manifold Gauge Set, Automatic Refrigerant Charging Meter and R-134a
supply tank following the Automatic Refrigerant
Charging Meter operating instructions.
3. Charge the refrigerant system following the Automatic Refrigerant Charging Meter operating
instructions.
4. If the refrigerant flow stops before the refrigerant charge is complete, start the engine, select
MAX A/C operation and allow the refrigerant charge
to complete.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air
Conditioning (A/C) System Recovery, Evacuation and Charging > Page 6078
Refrigerant: Service and Repair Refrigerant System Filtering Following Air Conditioning (A/C)
Compressor Installation
Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation
WARNING: Use extreme care and observe all safety and service precautions related to the use of
refrigerants as outlined on refrigerant tank and on recovery and charging equipment. Failure to
follow these instructions may result in serious personal injury.
NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any
vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If
the vehicle's A/C refrigerant is contaminated, refer the customer to the service facility that carried
out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery
equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C
refrigerant must be disposed of as hazardous waste. For all equipment, follow the equipment
manufacturer's procedures and instructions.
NOTICE: On vehicles being serviced for an internal compressor or desiccant failure, a new suction
accumulator or receiver/drier, Thermostatic Expansion Valve (TXV) or evaporator core orifice and
any hoses containing mufflers must be installed prior to filtering the Air Conditioning (A/C) system.
Internal plumbing of these devices makes it impossible to correctly remove any foreign material.
These components are typically discarded after A/C system contamination. Hoses without mufflers
can normally be reused unless they are clogged with foreign material. The filter is intended for use
on one vehicle only.
1. Orient the filter inlet toward the A/C condenser core.
2. NOTICE: The flexible extension adapters included in the A/C Flush Adapter Kit are designed for
low-pressure flushing and are not
designed for use with a charged refrigerant system. Do not make the condenser fitting connections
using the flexible extension adapters or damage to the adapters and loss of refrigerant will occur.
NOTE: The F8VZ-19E773-AB pancake filter is not permanently installed and will be removed at the
end of this procedure.
Disconnect the condenser outlet fitting and temporarily install the pancake filter between the 2
halves of the fitting.
- Use flexible refrigerant hose of 17,238 kPa (2,500 psi) burst rating.
- Make the connections using the correct adapters from the A/C Flush Adapter Kit and/or A/C Flush
and Purge Fitting Kit.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air
Conditioning (A/C) System Recovery, Evacuation and Charging > Page 6079
3. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional
information, refer to Refrigerant Oil Adding See:
Service and Repair/Refrigerant Oil Adding.
4. Evacuate and charge the refrigerant system. For additional information, refer to Air Conditioning
(A/C) System Recovery, Evacuation and
Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and
Charging.
5. Check all refrigerant system hoses, lines and the position of the newly installed filters to be sure
they do not interfere with other engine
compartment components. If necessary, use tie straps to make adjustments.
6. Provide adequate airflow to the front of the vehicle (with a fan, if necessary). Select A/C
operation and set the blower motor speed to maximum.
Start the engine and let it idle briefly. Make sure the A/C system is operating correctly.
7. Gradually bring the engine up to 1,200 rpm by running it at lower rpms for short periods (first at
800 rpm, then at 1,000 rpm). Set the engine at
1,200 rpm and run it for one hour with the A/C system operating.
8. Stop the engine.
9. Recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System
Recovery, Evacuation and Charging See: Service and
Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging.
10. Remove the adapters, flexible hoses and pancake filter from between the condenser and the
condenser to evaporator tube.
11. Discard the pancake filter. It can be used one time only.
12. Reconnect the condenser outlet fitting.
13. Evacuate, charge and leak-test the refrigerant system. For additional information, refer to Air
Conditioning (A/C) System Recovery, Evacuation
and Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and
Charging.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair
Refrigerant Oil: Service and Repair
Refrigerant Oil Adding
Refrigerant Oil Adding
NOTE: During normal A/C operation, oil is circulated through the system with the refrigerant, and a
small amount is retained in each component. If certain components of the system are removed,
some of the PAG oil will go with the component. To maintain the original total oil charge, it is
necessary to compensate for the oil lost by adding oil to the system with the new part.
1. Refer to the chart below for refrigerant oil adding amounts and methods of installation.
a If an excessive amount of PAG oil is lost due to a hose rupture/separation or other damage, the
total system PAG oil capacity must be added.
b The amount specified may be used for one or multiple O-ring leak repairs. Do not multiply the
PAG oil amount by the number of O-ring leaks being
repaired.
Adding Refrigerant Oil After A/C Compressor Replacement
Service A/C compressors shipped without clutch and pulley
1. Rotate the A/C compressor shaft 6 to 8 revolutions while collecting oil in a clean measuring
device.
- If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 oz), pour the
same amount plus 30 ml (1 oz) of clean PAG Refrigerant Compressor Oil (R-134a Systems)
(YN-12-D) WSH M1C231-B or equivalent into the new A/C compressor.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair >
Page 6083
- If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 oz),
pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) or
equivalent into the new A/C compressor.
- If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 oz), pour
85 ml (3 oz) of clean A/C Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new
A/C compressor.
Service A/C compressors shipped with clutch and pulley
2. Rotate the old A/C compressor shaft 6 to 8 revolutions while collecting oil in a clean measuring
device.
- If the amount of oil drained from the old A/C compressor is less than 89 ml (3 oz), remove 118 ml
(4 oz) from the new A/C compressor.
- If the amount of oil drained from the old A/C compressor is 89 ml (3 oz), remove 89 ml (3 oz) from
the new A/C compressor.
- If the amount of oil drained from the old A/C compressor is 118 ml (4 oz), remove 59 ml (2 oz)
from the new A/C compressor.
- If the amount of oil drained from the old A/C compressor is 148 ml (5 oz), remove 29 ml (1 oz)
from the new A/C compressor.
- If the amount of oil drained from the old A/C compressor is greater than 148 ml (5 oz), remove 0
ml (0 oz) from the new A/C compressor.
Adding Refrigerant Oil After New Suction Accumulator or Receiver/Drier Replacement
NOTE: This refrigerant oil adding method is to be used when a new suction accumulator or
receiver drier only has been installed. If a new A/C compressor and evaporator core orifice or TXV
have also been installed due to system contamination, refer to the appropriate heading.
1. Drill one 12.7 mm (1/2 in) hole in the old suction accumulator or receiver/drier cylinder and drain
the oil into a clean measuring cup.
2. Add the same quantity of new PAG oil, plus the amount collected during refrigerant recovery and
60 ml (2 fl oz).
Adding Refrigerant Oil After Multiple Component Replacement After A/C System Contamination
NOTE: This refrigerant oil adding method is to be used when a new A/C compressor, suction
accumulator or receiver drier and evaporator core orifice or TXV have been installed due to system
contamination and the A/C system has been flushed.
NOTE: Service A/C compressors are shipped without refrigerant oil.
1. Add 60 ml (2 fl oz) directly to the new A/C compressor suction port.
2. Inject the total vehicle PAG oil capacity minus 60 ml (2 fl oz) to the low-side service port during
system charging. For the total PAG oil capacity
specification, refer to the Specifications table.
Oil Injection Using a Dye/Lubricant Injector
NOTE: If fluorescent leak detection dye is also to be added during A/C charging, the dye may be
added to the dye/lubricant injector, from the R-134a Loop/Add On Injector Kit-Set, along with the
PAG oil.
1. Evacuate the refrigerant system. For additional information, refer to Air Conditioning (A/C)
System Recovery, Evacuation and Charging See:
Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging.
2. Assemble the dye/lubricant injector and the correct adapters from the R-134a Loop/Add On
Injector Kit-Set to match the amount of refrigerant
compressor oil to be injected.
3. Verify that all the valves on the dye/lubricant injector are closed.
4. Fill the dye/lubricant injector with the correct amount of clean, new PAG oil.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair >
Page 6084
5. Install the dye/lubricant injector between the low-side service gauge port valve and the
refrigerant service station or manifold gauge set.
6. Open all valves and charge the refrigerant system. For additional information, refer to Air
Conditioning (A/C) System Recovery, Evacuation and
Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and
Charging.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Locations
Refrigerant Pressure Sensor / Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Locations > Page 6088
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Diagrams > A/C Cycling Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Diagrams > A/C Cycling Switch > Page 6091
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Description and Operation > Air Conditioning (A/C) Cycling Switch
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Cycling
Switch
Engine Control Components
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 the Climate Control System Air Conditioning System Overview.
Also, refer to the applicable Wiring Diagrams for vehicle specific wiring.
If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate.
For additional information, refer to wide open throttle air conditioning cutoff (WAC).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Description and Operation > Air Conditioning (A/C) Cycling Switch > Page 6094
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) High
Pressure Switch
Engine Control Components
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 for 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 the Climate Control System, Air Conditioning System Overview
or the Wiring Diagrams.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Description and Operation > Air Conditioning (A/C) Cycling Switch > Page 6095
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Pressure (ACP)
Transducer Sensor
Engine Control Components
Air Conditioning Pressure (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.
A/C Pressure Transducer Sensor Output Voltage Vs Pressure Chart
Typical ACP Transducer Sensor
Typical ACP Transducer Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Auxiliary Blower Motor Relay
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Auxiliary Blower Motor Relay > Page 6101
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Auxiliary Blower Motor Relay > Page 6102
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Blower Motor Relay 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Blower Motor Relay 2 > Page 6105
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Auxiliary Blower Motor Relay
Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 6108
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 6109
Blower Motor Relay: Testing and Inspection Blower Motor Relay 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 6110
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 6111
Blower Motor Relay: Testing and Inspection Blower Motor Relay 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 6112
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 6116
Compressor Clutch Relay: Description and Operation
Engine Control Components
Air Conditioning (A/C) Clutch Relay (A/CCR)
Note: The PCM parameter identifiers (PIDs) wide open throttle air conditioning cutoff (WAC) and
wide open throttle air conditioning cutoff fault (WAC_F) 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 and the engine conditions are OK (coolant temperature, engine RPM, throttle position),
the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to the A/CCR.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 6117
Compressor Clutch Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 6118
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Locations > Page 6122
Control Module HVAC: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Locations > Page 6123
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 6128
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 6129
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 6130
Ambient Temperature Sensor / Switch HVAC: Testing and Inspection
Climate Control System
Component Tests
Temperature Sensor - Ambient
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Locations > Page 6134
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Locations > Page 6135
Blower Motor Switch: Service and Repair
Blower Motor Speed Control
Removal and Installation
1. Remove the blower motor speed control screw.
2. Remove the blower motor speed control.
3. Disconnect the blower motor speed control electrical connector.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations > Page 6139
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations > Page 6140
Cabin Temperature Sensor / Switch: Testing and Inspection
Climate Control System
Component Tests
Temperature Sensor - In-Vehicle
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Service and Repair > Ambient Air Temperature Sensor
Cabin Temperature Sensor / Switch: Service and Repair Ambient Air Temperature Sensor
Ambient Air Temperature Sensor
Removal and Installation
Mountaineer
1. Remove the radiator grille.
2. Remove the pin-type retainers and position the air deflector forward.
3. Remove the 2 air deflector pin-type retainers and detach the air deflector from the 2 locator pins
on the radiator support.
All vehicles
4. Detach the ambient air temperature sensor electrical connector.
5. Remove the ambient air temperature sensor.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Service and Repair > Ambient Air Temperature Sensor > Page 6143
Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor
In-Vehicle Temperature Sensor
Removal and Installation
1. Remove the instrument cluster finish panel.
2. Remove the in-vehicle temperature sensor.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
Air Conditioning Evaporator Temperature (ACET) Sensor
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 and improve defrost/demist
performance.
Note: These values can vary 15% due to sensor and VREF variations. Voltage values were
calculated for VREF equals 5.0 volts.
A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations
Refrigerant Pressure Sensor / Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations > Page 6150
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Diagrams > A/C Cycling Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Diagrams > A/C Cycling Switch > Page 6153
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Description and Operation > Air Conditioning (A/C) Cycling Switch
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Cycling
Switch
Engine Control Components
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 the Climate Control System Air Conditioning System Overview.
Also, refer to the applicable Wiring Diagrams for vehicle specific wiring.
If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate.
For additional information, refer to wide open throttle air conditioning cutoff (WAC).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Description and Operation > Air Conditioning (A/C) Cycling Switch > Page 6156
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) High
Pressure Switch
Engine Control Components
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 for 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 the Climate Control System, Air Conditioning System Overview
or the Wiring Diagrams.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Description and Operation > Air Conditioning (A/C) Cycling Switch > Page 6157
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Pressure (ACP)
Transducer Sensor
Engine Control Components
Air Conditioning Pressure (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.
A/C Pressure Transducer Sensor Output Voltage Vs Pressure Chart
Typical ACP Transducer Sensor
Typical ACP Transducer Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Locations > Page 6161
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and
Operation
Service Port HVAC: Description and Operation
Air Conditioning
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 (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations >
Page 6168
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service
and Repair
Vacuum Reservoir HVAC: Service and Repair
Vacuum Reservoir
Removal and Installation
1. Remove the vacuum reservoir screw.
2. Remove the vacuum reservoir.
3. Disconnect the vacuum connector.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information >
Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information >
Locations > Page 6175
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information >
Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment
Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After
A Supplemental Restraint System (SRS) Deployment
Inspection and Repair After a Supplemental Restraint System (SRS) Deployment
WARNING: Remove restraint system diagnostic tools from the vehicle prior to road testing. If tools
are not removed, the supplemental restraint system (SRS) device may not deploy in a crash.
Failure to follow this instruction may result in serious personal injury or death in a crash and
possibly violate vehicle safety standards.
NOTE: After diagnosing or repairing a Supplemental Restraint System (SRS), the restraint system
diagnostic tools (if required) must be removed before operating the vehicle over the road.
NOTE: Deployable devices (such as air bag modules, pretensioners) may deploy alone or in
various combinations depending on the impact event.
NOTE: Always refer to the appropriate diagnostic/repair information procedures prior to carrying
out vehicle repairs affecting the SRS and safety belt system.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. NOTE: Refer to the correct removal and installation procedure for all SRS components being
installed.
When any deployable device or combination of devices are deployed and/or the Restraints Control
Module (RCM) has the DTC B1231 (Event Threshold Exceeded) in memory, the repair of the
vehicle 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 be 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 Occupant Classification Sensor (OCS)
System Reset procedure as instructed in the diagnostic/repair information. Refer to the appropriate
diagnostic/repair information for OCS system removal and installation procedure.
When a vehicle has been involved in a collision and the Occupant Classification System Module
(OCSM) has DTC B1231/B1193:00 stored in memory, the repair of the OCS system is to include
the following procedures for the specified system: For rail-type OCS system, inspect the passenger side floorpan for damage and repair as
necessary. Install new OCS system rails. Do not install a new OCSM unless DTC B1231 cannot be
cleared.
- For weight sensor bolt-type OCS system, inspect the passenger side floorpan for damage and
repair as necessary. Install a new seat track with OCS system weight sensor bolts. DTC must be
cleared from the OCSM before carrying out Occupant Classification Sensor (OCS) System Reset.
Do not install a new OCSM unless DTC B1231/B1193:00 cannot be cleared.
- NOTE: Most bladder-type OCSM do not store a DTC B1231 in memory after deployment. The
DTC B1231 is stored only by the RCM.
For bladder-type OCS system, inspect for damage and repair as necessary. If installation of an
OCS system component is required, an OCS system service kit must be installed.
All vehicles
3. When any damage to the impact sensor mounting points or mounting hardware has occurred,
repair or install new mounting points and mounting
hardware as needed.
4. When the driver air bag module has deployed, a new clockspring must be installed.
5. New driver and/or front passenger safety belt systems (including retractors, buckles and height
adjusters) must be installed if the vehicle is
involved in a collision that results in deployment of the driver and/or front passenger safety belt
pretensioners. For additional information, refer to Seat Belt Systems.
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6181
- Instrument panel and mounting points
- Seats and seat mounting points
- Safety belts, safety belt buckles and safety belt retractors. For additional information, refer to Seat
Belt Systems.
- SRS wiring, wiring harnesses and connectors
7. After carrying out the review and inspection of the entire vehicle for damage, repair or install new
components as needed.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6182
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, 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). For additional information, refer to the appropriate procedure. Carry
out all applicable Functional Tests for the
component(s). For additional information, refer to the appropriate Functional Test procedure in
Safety Belt System See: Seat Belt Systems/Testing and Inspection/Component Tests and General
Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Depowering Procedure
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
may result in serious personal injury.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
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(R) and
cause serious personal injury or death.
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (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 RCM fuse 17 (10A) from the SJB.
For additional information, refer to the Wiring Diagram.
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 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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6188
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 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 an 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 (V6-4.0L (2009))
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 6189
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Deactivation and Reactivation
Supplemental Restraint System (SRS) Deactivation and Reactivation
Deactivation
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
may result in serious personal injury.
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.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
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.
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
All vehicles
1. Turn all vehicle accessories OFF.
2. Turn the ignition switch OFF.
3. At the Smart Junction Box (SJB), located below the LH side of the instrument panel, remove the
cover and RCM fuse 17 (10A) from the SJB. For
additional information, refer to the Wiring Diagrams.
4. Turn the ignition switch 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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6190
7. Remove the 2 driver air bag module bolts (1 shown).
8. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag
module.
9. Open and lower the glove compartment door.
10. Detach the wiring retainer, remove the 4 bolts and passenger air bag module heat shield.
11. NOTE: The canister vent and adaptive tether do not require deactivation.
Disconnect the LH side passenger air bag module electrical connector.
12. Under the rear of the passenger seat, detach the passenger seat side air bag module electrical
connector from the seat track bracket. Disengage the
passenger seat side air bag module electrical connector locking clip, release the tab and
disconnect the passenger seat side air bag module electrical connector.
Explorer and Mountaineer vehicles
13. Release and position aside the passenger side C-pillar trim panel.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6191
14. Disconnect the passenger side safety canopy module electrical connector.
15. Release and position aside the driver side C-pillar trim panel.
16. Disconnect the driver side safety canopy module electrical connector.
Explorer Sport Trac vehicles
17. Remove the driver and passenger side upper C-pillar trim panels.
18. Disconnect the passenger side safety canopy module electrical connector.
19. Disconnect the driver side safety canopy module electrical connector.
All vehicles
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6192
20. Under driver seat, the rear of the slide and disengage the driver seat side air bag module
electrical connector locking clip, release the tab and
disconnect the driver seat side air bag module electrical connector.
21. Install the RCM fuse 17 (10A) to the SJB.
22. 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. Connect the driver seat side air bag module electrical connector and engage the seat side air
bag electrical connector locking clip.
Explorer Sport Trac vehicles
4. Connect the driver side safety canopy module electrical connector.
5. Connect the passenger side safety canopy module electrical connector.
6. Install the driver and passenger upper C-pillar trim panels.
Explorer and Mountaineer vehicles
7. Connect the driver side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6193
8. Install the driver side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
9. Connect the passenger side safety canopy module electrical connector.
10. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles
11. Connect the passenger seat side air bag module electrical connector and engage the seat side
air bag electrical connector locking clip. Attach the
passenger seat side air bag module electrical connector to the seat track bracket.
12. Connect the LH side passenger air bag module electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6194
13. Install the passenger air bag module heat shield and 4 bolts. Attach the wiring retainer.
14. NOTICE: 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.
15. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
16. Turn the ignition switch from OFF to ON.
17. Install RCM fuse 17 (10A) to the SJB and install the cover.
18. 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.
19. 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 an 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 (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air
Bag Module, Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air
Bag Module, Left > Page 6199
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air
Bag Module, Left > Page 6200
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 6203
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 6204
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 6205
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 6206
Air Bag: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 6207
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 6208
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 6209
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 6210
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 6211
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 6212
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Air Bag Trim Cover - Passenger
Air Bag: Service and Repair Air Bag Trim Cover - Passenger
Air Bag Trim Cover - Passenger
Removal
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.
WARNING: Do not use any sharp tools to separate the passenger air bag module trim cover from
the passenger air bag module canister. Sharp tools may damage the passenger air bag module.
Failure to follow this instruction may result in the passenger air bag module deploying incorrectly
and increases the risk of serious personal injury or death in a crash.
WARNING: Do not unpack or unroll the passenger air bag module soft pack. If the soft pack
becomes unpacked or unrolled, install a new passenger air bag module assembly. Failure to follow
these instructions may result in the passenger air bag module deploying incorrectly and increases
the risk of serious personal injury or death in a crash.
WARNING: Do not manipulate or compromise the passenger air bag module hooks during the
removal or installation procedure. Failure to follow this instruction may result in the passenger air
bag module deploying incorrectly and increases the risk of serious personal injury or death in a
crash.
1. Remove the passenger air bag module. For additional information, refer to Passenger Air Bag
Module See: Passenger Air Bag Module.
2. Place a mark on top of the passenger air bag module canister for correct installation.
3. Carefully lift the passenger air bag module cover from the bottom of the air bag module canister,
separating the windows from the canister hooks.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Air Bag Trim Cover - Passenger > Page 6215
4. NOTE: Place an X mark on the old air bag cover to avoid reinstalling.
Remove the passenger air bag cover from the canister, separating the top windows from the
canister hooks.
Installation
1. Place the passenger air bag cover on a clean work surface once it is removed from the shipping
package.
2. WARNING: Carefully inspect the passenger air bag trim cover, canister and soft pack before
assembly. If any foreign objects are found,
remove them before attaching the passenger air bag trim cover to the canister. If the canister or
soft pack is damaged, install a new passenger air bag module assembly. Failure to follow this
instruction may result in the passenger air bag module deploying incorrectly, which increases the
risk of serious personal injury or death in a crash.
Match the number of cover windows to the number of canister hooks before attaching the
passenger air bag cover to the canister.
3. Match the top of the passenger air bag cover with the canister mark from the removal procedure.
4. Position the canister onto the passenger air bag cover and engage the bottom hooks into the air
bag cover windows.
5. Push the top of the passenger air bag cover to engage the top canister hooks.
6. Inspect the passenger air bag cover windows-to-canister hooks to verify that every window has a
hook installed and the sides are not tucked or
folded against the air bag canister.
7. Install the passenger air bag module. For additional information, refer to Passenger Air Bag
Module See: Passenger Air Bag Module.
8. NOTE: The video procedure utilizes a Fusion/Milan passenger air bag module assembly. It also
applies to vehicles with similar passenger air bag
module designs.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Air Bag Trim Cover - Passenger > Page 6216
Air Bag: Service and Repair Driver Air Bag Module
Driver Air Bag Module
Removal
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.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
2. Remove the 2 driver air bag module bolts.
- To install, tighten to 7 Nm (62 lb-in).
3. NOTE: Match 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. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Air Bag Trim Cover - Passenger > Page 6217
Air Bag: Service and Repair Passenger Air Bag Module
Passenger Air Bag Module
Removal and Installation
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.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
NOTICE: Do not install a new passenger air bag module assembly due to a damaged or discolored
passenger air bag cover. The passenger air bag cover can be serviced separately from the
passenger air bag module assembly. For additional information, refer to Air Bag Trim Cover Passenger See: Air Bag Trim Cover - Passenger.
NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
2. Open and lower the glove compartment door.
3. Release the wiring retainer, 4 bolts and passenger air bag module heat shield.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Air Bag Trim Cover - Passenger > Page 6218
4. Disconnect the 2 passenger air bag module electrical connectors.
5. Remove the 4 passenger air bag module nuts.
- To install, tighten to 9 Nm (80 lb-in).
6. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the passenger
air bag cover. Damage to the air bag
module may occur.
Push up to release the passenger air bag cover clips from the instrument panel and remove the
passenger air bag module.
7. NOTE: During passenger air bag module installation, make sure all of the air bag trim cover clips
are fully seated into the instrument panel.
To install, reverse the removal procedure.
8. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Air Bag Trim Cover - Passenger > Page 6219
Air Bag: Service and Repair Safety Canopy Module
Safety Canopy Module - Explorer, Mountaineer
NOTE: RH shown, LH similar.
Removal
WARNING: Anytime the Safety Canopy(R) 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(R) or side
air curtain module deploying incorrectly and increases the risk of serious personal injury or death in
a crash.
WARNING: Always carry or place a live Safety Canopy(R), 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.
WARNING: Do not obstruct or place objects in the deployment path of the Safety Canopy(R) or
side air curtain module. Failure to follow this instruction may result in the Safety Canopy(R) or side
air curtain module deploying incorrectly and increases the risk of serious personal injury or death in
a crash.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain
modules. Failure to follow this instruction
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Air Bag Trim Cover - Passenger > Page 6220
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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
All vehicles
1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
2. Remove the headliner.
Vehicles with auxiliary climate control
3. Remove the 2 retainers and auxiliary climate control headliner duct from the C-pillar.
All vehicles
4. NOTE: Note the safety canopy module wiring harness routing 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 front tether anchor bracket.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Air Bag Trim Cover - Passenger > Page 6221
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.
10. Remove the safety canopy module 3 bolts near the C-pillar.
11. Remove the safety canopy module 2 rear bracket bolts.
12. Remove the safety canopy module bolt at the B-pillar.
13. Gently lift the safety canopy module up and inward at the B-pillar to release the bracket hook
from the sheet metal.
14. Move the safety canopy module forward to release the rear bracket hook from the sheet metal
and remove the safety canopy module.
Installation
WARNING: Never put any type of fastener or tie strap around any part of a Safety Canopy(R)
module, side air curtain module or interior trim panel. This will prevent the Safety Canopy(R) 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.
WARNING: Always carry or place a live Safety Canopy(R), 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.
WARNING: When installing a new headliner on a vehicle equipped with Safety Canopy(R) 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(R) or side air curtain module not deploying or deploying
incorrectly, increasing the risk of personal injury or death in a crash.
WARNING: Always use new torque-prevailing type J-nuts when installing the Safety Canopy(R) 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(R) module deploying incorrectly
and increases the risk of serious personal injury or death in a crash.
WARNING: Before installing a Safety Canopy(R) 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(R) or side air curtain deploying incorrectly, which
increases the risk of serious personal injury or death in a crash.
WARNING: Inspect a Safety Canopy(R) or side air curtain module before installation. If the module
is damaged, the cover has separated or the Safety Canopy(R) or 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(R) or side air curtain deploying incorrectly, which
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 (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Air Bag Trim Cover - Passenger > Page 6222
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.
- 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. Attach the 3 safety canopy module front tether pin-type retainers to the A-pillar.
10. 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
11. NOTE: Make sure to route the entertainment system wiring as noted during removal.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Air Bag Trim Cover - Passenger > Page 6223
Attach the 2 entertainment system wiring retainers.
Vehicles with moon roof
12. 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
13. 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
14. Install the auxiliary climate control headliner duct and 2 retainers to the C-pillar.
All vehicles
15. Install the headliner.
16. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Air Bag Trim Cover - Passenger > Page 6224
Air Bag: Service and Repair Side Air Bag Module
Side Air Bag Module
NOTE: Driver seat shown, passenger similar.
Removal
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.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
WARNING: 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.
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.
NOTICE: 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: 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 air bag warning indicator illuminates
when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
2. Remove the front seat.
3. Remove the seat backrest.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Air Bag Trim Cover - Passenger > Page 6225
4. 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.
5. Release the seat back lower outer trim cover J-clip.
6. Release the seat back lower inner trim cover J-clip.
7. 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.
NOTICE: 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.
8. Remove the first row of hog rings.
9. Detach the hook-and-loop strips and invert the seat backrest trim cover up enough to expose the
side air bag.
10. 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Air Bag Trim Cover - Passenger > Page 6226
11. Position out the seat backrest foam pad.
12. 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.
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.
WARNING: 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.
NOTICE: 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Air Bag Trim Cover - Passenger > Page 6227
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.
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.
Driver Seat
11. Install the driver seat and repower the SRS.
Passenger seat
12. Install the passenger seat and repower the SRS. Do not prove out the SRS at this time.
13. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS. For additional information, refer to
Occupant Classification Sensor (OCS) System Zero Seat Weight Test See: Testing and
Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations
Air Bag Control Module: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 6231
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 6232
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Diagrams > Driver Can Vent Unit
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Diagrams > Driver Can Vent Unit > Page 6235
Air Bag Control Module: Diagrams Restraints Control Module (RCM)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Diagrams > Driver Can Vent Unit > Page 6236
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Diagrams > Driver Can Vent Unit > Page 6237
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Diagrams > Page 6238
Air Bag Control Module: Service and Repair
Restraints Control Module (RCM)
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(R) and
cause serious personal injury or death.
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.
NOTICE: When installing a new Restraints Control Module (RCM), it is necessary to carry out
Programmable Module Installation (PMI). Failure to follow these instructions may result in
component damage and/or system failure. See: Powertrain Management/Computers and Control
Systems/Information Bus/Testing and Inspection/Programming and Relearning
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.
NOTE: The air bag warning indicator illuminates when the correct RCM fuse is removed and the
ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. If installing a new RCM, carry out the steps necessary to prepare for Programmable Module
Installation (PMI). See: Powertrain
Management/Computers and Control Systems/Information Bus/Testing and
Inspection/Programming and Relearning
2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Diagrams > Page 6239
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 (106 lb-in).
3. Connect the small RCM electrical connector.
4. NOTE: The RCM has been removed for clarity.
On the large RCM electrical connector, place the connector position assurance lever in the full
release position.
5. NOTICE: Putting the large electrical connector into the Restraints Control Module (RCM) on an
angle may cause bad electrical
connections and damage components.
Position the large electrical connector into the RCM.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Diagrams > Page 6240
6. Connect the large RCM connector.
- NOTICE: 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 electrical connector uniformly aligned to the RCM, lightly push in until a subtle
audible click is heard and a slight resistance is felt.
- Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into
the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.
7. Install the front floor console.
8. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to
Supplemental Restraint System (SRS) Depowering
and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental
Restraint System (SRS) Depowering and Repowering in the General Procedures.
9. When installing a new RCM, carry out the steps necessary to complete Programmable Module
Installation (PMI). See: Powertrain
Management/Computers and Control Systems/Information Bus/Testing and
Inspection/Programming and Relearning
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 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 an 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 (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information
> Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information
> Diagrams > Page 6244
Air Bag Deactivation Indicator: Service and Repair
Passenger Air Bag Deactivation (PAD) Indicator
Removal and Installation
1. NOTE: Ignition must be OFF if disconnecting the Passenger Air Bag Deactivation (PAD)
indicator electrical connector. Otherwise, a DTC will be
set in the Restraints Control Module (RCM) memory and must be cleared before releasing the
vehicle.
Turn the ignition OFF and wait at least one minute.
2. Remove the floor console.
3. Gently pull outward to release the clips on the instrument panel center finish panel.
4. Disconnect the PAD indicator electrical connector.
5. Remove the 2 screws and PAD indicator.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams
Clockspring Assembly / Spiral Cable: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 6248
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 6249
Clockspring Assembly / Spiral Cable: Service and Repair
Clockspring
Removal
NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Remove the driver air bag module. For additional information, refer to Driver Air Bag Module
See: Air Bag/Service and Repair/Driver Air Bag
Module.
2. Remove the steering wheel.
3. Remove the 2 screws and instrument panel lower steering column opening cover.
4. Remove the 3 screws and lower steering column shroud.
5. Remove the upper steering column shroud.
6. Disconnect the clockspring electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 6250
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. NOTICE: 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 2 screws.
2. Install the steering wheel rotation sensor and 2 screws.
3. Connect the clockspring electrical connector.
4. Install the upper steering column shroud.
5. Install the lower steering column shroud and 3 screws.
6. Install the instrument panel lower steering column opening cover and 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.
NOTICE: To prevent component damage and/or system failure, when reusing a clockspring it must
be centered.
NOTICE: 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 revolutions to
center the clockspring. The clockspring inner rotor, wiring and connector must be in the 12 o'clock position.
9. NOTICE: 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.
Install the steering wheel.
10. If a new clockspring was installed, remove the anti-rotation key.
11. Install the driver air bag module. For additional information, refer to Driver Air Bag Module See:
Air Bag/Service and Repair/Driver Air Bag
Module.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor
Impact Sensor: Locations RH Front Impact Severity Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6255
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6256
Impact Sensor: Locations LH Front Impact Severity Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6257
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6258
Impact Sensor: Locations Side Impact Sensor, Second Row Driver Side
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6259
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6260
Impact Sensor: Locations Side Impact Sensor, Second Row Passenger Side
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6261
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6262
Impact Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6263
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6264
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6265
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6266
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6267
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6268
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6269
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6270
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
RH Front Impact Severity Sensor > Page 6271
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Side Impact Sensor, First Row Driver Side
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Side Impact Sensor, First Row Driver Side > Page 6274
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Side Impact Sensor, First Row Driver Side > Page 6275
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Side Impact Sensor, First Row Driver Side > Page 6276
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Side Impact Sensor, First Row Driver Side > Page 6277
Impact Sensor: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Side Impact Sensor, First Row Driver Side > Page 6278
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Side Impact Sensor, First Row Driver Side > Page 6279
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor
Impact Sensor: Service and Repair Front Impact Severity Sensor
Front Impact Severity Sensor
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
2. Remove the 4 pin-type retainers and 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 front impact severity sensor. To install, tighten to 12 Nm (106 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor > Page 6282
6. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor > Page 6283
Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar
Side Impact Sensor - C-Pillar, Explorer, Mountaineer
NOTE: RH shown, LH similar.
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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
NOTE: The LH and RH C-pillar mounted side impact sensors are not interchangeable.
1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
2. Remove the rear door scuff plate.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor > Page 6284
NOTE: 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 (106 lb-in).
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. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor > Page 6285
Impact Sensor: Service and Repair Side Impact Sensor - Front Door
Side Impact Sensor - Front Door
NOTE: LH side shown, RH similar.
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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
2. Remove the front interior door trim panel.
3. Detach the rearward lower corner of the weathershield on the door to access the side impact
sensor (pressure sensor).
4. Disconnect the electrical connector.
5. Remove the bolt and 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. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag >
Component Information > Locations > Page 6289
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag >
Component Information > Locations > Page 6290
Seat Occupant Classification Module - Air Bag: Service and Repair
Occupant Classification System Module (OCSM)
NOTE: Power seat shown, manual seat similar.
Removal
NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
2. Disconnect the Occupant Classification System Module (OCSM) electrical connector underneath
the front of the passenger seat.
3. NOTE: Note the position of the locator tab on the OCSM for installation.
Remove the 2 screws and the OCSM.
4. To install, reverse the removal procedure.
5. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to
Supplemental Restraint System (SRS) Depowering
and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental
Restraint System (SRS) Depowering and Repowering in the General Procedures.
6. Carry out the appropriate procedure after installation of an Occupant Classification Sensor
(OCS) system component.
- If installing the original OCS system component, carry out the OCS System Zero Seat Weight
Test and prove out the SRS. For additional information, refer to Occupant Classification Sensor
(OCS) System Zero Seat Weight Test See: Testing and Inspection/Component Tests and General
Diagnostics.
- If installing a new OCS system component, carry out the OCS Reset and prove out the SRS. For
additional information, refer to Occupant Classification Sensor (OCS) System Reset See: Service
and Repair/Occupant Classification Sensor (OCS) System Reset.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > OCS Rail 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > OCS Rail 1 > Page 6295
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > Page 6296
Seat Occupant Sensor: Service and Repair
Occupant Classification Sensor
NOTE: Outboard Occupant Classification Sensor (OCS) rail shown, inboard similar.
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.
WARNING: 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.
WARNING: 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.
WARNING: 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > Page 6297
crash.
NOTICE: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Remove the front passenger seat.
2. NOTICE: 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 Occupant Classification Sensor (OCS) rail position, electrical wiring routing, wiring,
connector and wiring retainers for installation.
On the affected side, detach the 2 OCS rail wiring retainers and using a suitable tool, release the
tab and disconnect the OCS rail electrical connector.
3. If equipped, disconnect the power seat track motor electrical connector.
4. Move the seat to the forward stop position.
- If equipped with a power seat track, apply power and ground to the pins shown.
5. Remove the 2 rear bolts from the OCS rail.
6. Move the seat to the rearward stop position.
- If equipped with a power seat track, apply power and ground to the pins shown.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > Page 6298
7. NOTE: Note the locator tab position where the OCS rail goes through the rail shield and into the
rear seat track mounting point for installation.
Remove the 2 front bolts and OCS rail and shield.
Installation
NOTE: If installing a new seat track, position the seat track where the seat will be in the full
rearward position before installing the OCS rails.
NOTE: 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.
NOTICE: 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: Make sure the OCS rail shield is seated correctly on the OCS rail.
Install the shield on the OCS rail, and install the OCS rail and shield on the seat track with the
locator tab aligned correctly as shown.
2. Hold the OCS rail and shield firmly in position and install the front mounting position rear bolt.
- Tighten to 25 Nm (18 lb-ft).
3. Hold the OCS rail and shield firmly in position and install the front mounting position front bolt.
- Tighten to 25 Nm (18 lb-ft).
4. Move the seat to the forward stop position.
- If equipped with a power seat track, apply power and ground to the pins shown.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > Page 6299
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, route the 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 component, carry out the Occupant Classification Sensor
(OCS) System Zero Seat Weight Test and prove out the SRS. For additional information, refer to
Occupant Classification Sensor (OCS) System Zero Seat Weight Test See: Testing and
Inspection/Component Tests and General Diagnostics.
- If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS)
System Reset procedure and prove out the SRS. For additional information, refer to Occupant
Classification Sensor (OCS) System Reset See: Service and Repair/Occupant Classification
Sensor (OCS) System Reset.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
NOTE: Power seat shown, manual seat similar.
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.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Position the front seat to the rearmost and upward position.
2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
3. Disconnect the seat position sensor 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.
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. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations
Air Bag Control Module: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 6307
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 6308
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Driver Can Vent Unit
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Driver Can Vent Unit > Page 6311
Air Bag Control Module: Diagrams Restraints Control Module (RCM)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Driver Can Vent Unit > Page 6312
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Driver Can Vent Unit > Page 6313
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Page 6314
Air Bag Control Module: Service and Repair
Restraints Control Module (RCM)
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(R) and
cause serious personal injury or death.
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.
NOTICE: When installing a new Restraints Control Module (RCM), it is necessary to carry out
Programmable Module Installation (PMI). Failure to follow these instructions may result in
component damage and/or system failure. See: Powertrain Management/Computers and Control
Systems/Information Bus/Testing and Inspection/Programming and Relearning
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.
NOTE: The air bag warning indicator illuminates when the correct RCM fuse is removed and the
ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. If installing a new RCM, carry out the steps necessary to prepare for Programmable Module
Installation (PMI). See: Powertrain
Management/Computers and Control Systems/Information Bus/Testing and
Inspection/Programming and Relearning
2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag
Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System
(SRS) Depowering and Repowering in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Page 6315
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 (106 lb-in).
3. Connect the small RCM electrical connector.
4. NOTE: The RCM has been removed for clarity.
On the large RCM electrical connector, place the connector position assurance lever in the full
release position.
5. NOTICE: Putting the large electrical connector into the Restraints Control Module (RCM) on an
angle may cause bad electrical
connections and damage components.
Position the large electrical connector into the RCM.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Page 6316
6. Connect the large RCM connector.
- NOTICE: 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 electrical connector uniformly aligned to the RCM, lightly push in until a subtle
audible click is heard and a slight resistance is felt.
- Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into
the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.
7. Install the front floor console.
8. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to
Supplemental Restraint System (SRS) Depowering
and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and
Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General
Procedures.
9. When installing a new RCM, carry out the steps necessary to complete Programmable Module
Installation (PMI). See: Powertrain
Management/Computers and Control Systems/Information Bus/Testing and
Inspection/Programming and Relearning
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 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 an 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 (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Locations > Page 6320
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Locations > Page 6321
Seat Occupant Classification Module - Air Bag: Service and Repair
Occupant Classification System Module (OCSM)
NOTE: Power seat shown, manual seat similar.
Removal
NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag
Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System
(SRS) Depowering and Repowering in the General Procedures.
2. Disconnect the Occupant Classification System Module (OCSM) electrical connector underneath
the front of the passenger seat.
3. NOTE: Note the position of the locator tab on the OCSM for installation.
Remove the 2 screws and the OCSM.
4. To install, reverse the removal procedure.
5. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to
Supplemental Restraint System (SRS) Depowering
and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and
Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General
Procedures.
6. Carry out the appropriate procedure after installation of an Occupant Classification Sensor
(OCS) system component.
- If installing the original OCS system component, carry out the OCS System Zero Seat Weight
Test and prove out the SRS. For additional information, refer to Occupant Classification Sensor
(OCS) System Zero Seat Weight Test See: Air Bag Systems/Testing and Inspection/Component
Tests and General Diagnostics.
- If installing a new OCS system component, carry out the OCS Reset and prove out the SRS. For
additional information, refer to Occupant Classification Sensor (OCS) System Reset See: Air Bag
Systems/Service and Repair/Occupant Classification Sensor (OCS) System Reset.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Depowering Procedure
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
may result in serious personal injury.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
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(R) and
cause serious personal injury or death.
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (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 RCM fuse 17 (10A) from the SJB.
For additional information, refer to the Wiring Diagram.
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 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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6327
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 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 an 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 (V6-4.0L (2009))
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 6328
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Deactivation and Reactivation
Supplemental Restraint System (SRS) Deactivation and Reactivation
Deactivation
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
may result in serious personal injury.
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.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
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.
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
All vehicles
1. Turn all vehicle accessories OFF.
2. Turn the ignition switch OFF.
3. At the Smart Junction Box (SJB), located below the LH side of the instrument panel, remove the
cover and RCM fuse 17 (10A) from the SJB. For
additional information, refer to the Wiring Diagrams.
4. Turn the ignition switch 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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6329
7. Remove the 2 driver air bag module bolts (1 shown).
8. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag
module.
9. Open and lower the glove compartment door.
10. Detach the wiring retainer, remove the 4 bolts and passenger air bag module heat shield.
11. NOTE: The canister vent and adaptive tether do not require deactivation.
Disconnect the LH side passenger air bag module electrical connector.
12. Under the rear of the passenger seat, detach the passenger seat side air bag module electrical
connector from the seat track bracket. Disengage the
passenger seat side air bag module electrical connector locking clip, release the tab and
disconnect the passenger seat side air bag module electrical connector.
Explorer and Mountaineer vehicles
13. Release and position aside the passenger side C-pillar trim panel.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6330
14. Disconnect the passenger side safety canopy module electrical connector.
15. Release and position aside the driver side C-pillar trim panel.
16. Disconnect the driver side safety canopy module electrical connector.
Explorer Sport Trac vehicles
17. Remove the driver and passenger side upper C-pillar trim panels.
18. Disconnect the passenger side safety canopy module electrical connector.
19. Disconnect the driver side safety canopy module electrical connector.
All vehicles
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6331
20. Under driver seat, the rear of the slide and disengage the driver seat side air bag module
electrical connector locking clip, release the tab and
disconnect the driver seat side air bag module electrical connector.
21. Install the RCM fuse 17 (10A) to the SJB.
22. 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. Connect the driver seat side air bag module electrical connector and engage the seat side air
bag electrical connector locking clip.
Explorer Sport Trac vehicles
4. Connect the driver side safety canopy module electrical connector.
5. Connect the passenger side safety canopy module electrical connector.
6. Install the driver and passenger upper C-pillar trim panels.
Explorer and Mountaineer vehicles
7. Connect the driver side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6332
8. Install the driver side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
9. Connect the passenger side safety canopy module electrical connector.
10. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles
11. Connect the passenger seat side air bag module electrical connector and engage the seat side
air bag electrical connector locking clip. Attach the
passenger seat side air bag module electrical connector to the seat track bracket.
12. Connect the LH side passenger air bag module electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6333
13. Install the passenger air bag module heat shield and 4 bolts. Attach the wiring retainer.
14. NOTICE: 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.
15. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
16. Turn the ignition switch from OFF to ON.
17. Install RCM fuse 17 (10A) to the SJB and install the cover.
18. 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.
19. 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 an 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 (V6-4.0L (2009))
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, 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: Second row bucket seats shown, others similar.
NOTE: Carpet removed for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6339
1. Remove the bolt(s) and tether anchor(s).
- To install, apply clear silicone rubber and tighten to 40 Nm (30 lb-ft).
2. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6340
Child Seat Tether Attachment: Service and Repair Child Safety Seat Tether Anchor - Third Row
Child Safety Seat Tether Anchor - Third Row
Removal and Installation
WARNING: 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, 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 (V6-4.0L (2009))
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 6341
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, apply clear silicone rubber and tighten to 40 Nm (30 lb-ft).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Description and Operation
Seat Belt Buckle: Description and Operation
Safety Belt System
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, 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.
When replacing any active occupant restraint components, use only the replacement parts
specified in the Ford Customer Service Division Master Parts and Accessories Catalog.
Safety Belt Buckles
Safety belt buckle and pretensioner
The safety belt buckle and pretensioners are located on the inboard side of the seat track and is for
front seat occupants.
The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from
the safety belt system when deployed. When the pretensioner deploys, the buckle moves
downward, removing excess webbing from the lap and shoulder safety belts.
If the vehicle is involved in a crash that results in pretensioner deployment, a new safety belt buckle
pretensioner must be installed.
For safety belt buckle pretensioner diagnosis and disposal information, refer to Diagnosis and
Testing or General Procedures in Air Bag Systems. See: Air Bag Systems/Testing and Inspection
Second and third row safety belt buckles
The second and third row safety belt buckles are attached to the seat cushion frames or floor and
can be serviced separately.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Description and Operation > Page 6345
Seat Belt Buckle: Testing and Inspection
Safety Belt System
Component Test
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, 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.
Carry out the appropriate Functional Test(s) as determined in Inspection and Verification.
Functional Test - Safety Belt 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 safety belt buckle latches the tongue.
2. Verify the system integrity by forcefully pulling on the safety belt webbing.
3. Unlatch the safety belt by fully depressing the safety belt buckle release button and allowing the
safety belt to release and retract.
4. Verify the following during the unlatching process:
- Push-button depression does not require excessive effort.
- The tongue can be removed easily from the buckle.
5. Repeat the above steps 3 times.
6. If the functional test reveals a concern(s), install a new safety belt buckle or safety belt retractor
as required.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket
Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, Bucket
Safety Belt Buckle - Second Row, Bucket
Removal and Installation
WARNING: 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, 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 seat base cover.
3. Remove the bolt and safety belt buckle.
- To install, apply clear silicone rubber and tighten to 47 Nm (35 lb-ft).
4. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6348
To install, reverse the removal procedure.
5. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System See: Testing and Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6349
Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, Center And RH, 60/40,
Bench
Safety Belt Buckle - Second Row, Center and RH, 60/40, Bench
Removal and Installation
WARNING: 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, 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.
1. Remove the 2 bolts and dual safety belt buckle.
- To install, tighten to 40 Nm (30 lb-ft).
2. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
3. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System See: Testing and Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6350
Seat Belt Buckle: Service and Repair 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, 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 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
3. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System See: Testing and Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6351
Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, LH, 60/40, Bench
Safety Belt Buckle - Second Row, LH, 60/40, Bench
Removal and Installation
WARNING: 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, 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 40 percent seat.
2. Remove the bolt and safety belt buckle.
- To install, tighten to 55 Nm (41 lb-ft).
3. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
4. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System See: Testing and Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6352
Seat Belt Buckle: Service and Repair
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, 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 seat base cover.
3. Remove the bolt and safety belt buckle.
- To install, apply clear silicone rubber and tighten to 47 Nm (35 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6353
4. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
5. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System See: Testing and Inspection/Component Tests and General Diagnostics.
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, 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.
1. Remove the 2 bolts and dual safety belt buckle.
- To install, tighten to 40 Nm (30 lb-ft).
2. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6354
3. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System See: Testing and Inspection/Component Tests and General Diagnostics.
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, 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 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
3. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System See: Testing and Inspection/Component Tests and General Diagnostics.
Safety Belt Buckle - Second Row, LH, 60/40, Bench
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6355
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, 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 40 percent seat.
2. Remove the bolt and safety belt buckle.
- To install, tighten to 55 Nm (41 lb-ft).
3. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
4. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System See: Testing and Inspection/Component Tests and General Diagnostics.
Safety Belt Buckle - Second Row, LH, 60/40, E-Z Entry
Safety Belt Buckle - Second Row, LH, 60/40, E-Z Entry
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6356
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, 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 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
5. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System See: Testing and Inspection/Component Tests and General Diagnostics.
Safety Belt Buckle - Third Row
Safety Belt Buckle - Third Row
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6357
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, 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: 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
4. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System See: Testing and Inspection/Component Tests and General Diagnostics.
Safety Belt Buckle And Pretensioner
Safety Belt Buckle and Pretensioner
NOTE: LH shown, RH similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6358
Removal and Installation
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
may result in serious personal injury.
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, 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Position the seat so it does not engage the safety belt buckle and pretensioner bracket and
allows access to all 4 seat mounting fasteners.
- If equipped with power seats, position the passenger seat track downward to access the safety
belt retractor anchor bolt.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6359
2. Remove the 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
7. Install the seat and repower the SRS. If the passenger seat has been serviced, do not prove out
the SRS at this time.
8. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System See: Testing and Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Locations > Safety Belt Buckle Switch, Passenger
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Locations > Safety Belt Buckle Switch, Passenger > Page 6364
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Diagrams > Safety Belt Buckle Switch, Driver
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Diagrams > Safety Belt Buckle Switch, Driver > Page 6367
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
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, 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.
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 shoulder 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Page 6371
1. Rotate the safety belt shoulder height adjuster downward to release the lower tab.
2. Remove the safety belt shoulder height adjuster.
7. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
8. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System See: Testing and Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 System
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, 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.
When replacing any active occupant restraint components, use only the replacement parts
specified in the Ford Customer Service Division Master Parts and Accessories Catalog.
Safety Belt Warning System
The safety belt warning system is a reminder to fasten the driver safety belt. Refer to Diagnosis
and Testing, Safety Belt System See: Testing and Inspection/Component Tests and General
Diagnostics.
Belt-Minder(R)
The Belt-Minder(R) feature is a supplemental warning to the safety belt warning function. This
feature provides additional reminders to the driver that the driver safety belt is unbuckled. Refer to
Diagnosis and Testing, Safety Belt System See: Testing and Inspection/Component Tests and
General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information
> Description and Operation > Page 6375
Seat Belt Reminder Buzzer: Service and Repair
Belt-Minder(R) Deactivating/Activating
Preparation
NOTE: The Belt-Minder(R) Deactivating/Activating procedure can also be carried out using the
scan tool.
1. Apply the parking brake before deactivating/activating the Belt-Minder(R).
2. Place the gear selector lever in PARK (P).
3. Place the ignition switch in the OFF position.
4. Close all the vehicle doors.
5. Unbuckle the driver and the front passenger safety belts.
Deactivating/Activating
1. Turn the ignition switch to the ON position (do not start the engine).
2. Wait until the safety belt warning indicator turns off (approximately 1 minute).
3. NOTE: Step 3 must be completed within 50 seconds after the safety belt warning indicator turns
off.
For the seating position being disabled, at a moderate speed, buckle then unbuckle the safety belt
9 times, ending with the safety belt in the unbuckled state. After this step the safety belt warning
indicator illuminates for 3 seconds.
4. Within 5 seconds after the safety belt warning indicator turns off, at a moderate speed, buckle
then unbuckle the safety belt.
- This disables the Belt-Minder(R) feature for that seating position, if it is currently enabled. As
confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds.
- This enables the Belt-Minder(R) feature for that seating position, if it is currently disabled. As
confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds followed by
a second flash sequence after a brief pause.
5. After confirmation, the deactivation/activation procedure is complete.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 System
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, 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.
When replacing any active occupant restraint components, use only the replacement parts
specified in the Ford Customer Service Division Master Parts and Accessories Catalog.
Safety Belt Warning System
The safety belt warning system is a reminder to fasten the driver safety belt. Refer to Diagnosis
and Testing, Safety Belt System See: Testing and Inspection/Component Tests and General
Diagnostics.
Belt-Minder(R)
The Belt-Minder(R) feature is a supplemental warning to the safety belt warning function. This
feature provides additional reminders to the driver that the driver safety belt is unbuckled. Refer to
Diagnosis and Testing, Safety Belt System See: Testing and Inspection/Component Tests and
General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information >
Description and Operation > Page 6379
Seat Belt Reminder Lamp: Service and Repair
Belt-Minder(R) Deactivating/Activating
Preparation
NOTE: The Belt-Minder(R) Deactivating/Activating procedure can also be carried out using the
scan tool.
1. Apply the parking brake before deactivating/activating the Belt-Minder(R).
2. Place the gear selector lever in PARK (P).
3. Place the ignition switch in the OFF position.
4. Close all the vehicle doors.
5. Unbuckle the driver and the front passenger safety belts.
Deactivating/Activating
1. Turn the ignition switch to the ON position (do not start the engine).
2. Wait until the safety belt warning indicator turns off (approximately 1 minute).
3. NOTE: Step 3 must be completed within 50 seconds after the safety belt warning indicator turns
off.
For the seating position being disabled, at a moderate speed, buckle then unbuckle the safety belt
9 times, ending with the safety belt in the unbuckled state. After this step the safety belt warning
indicator illuminates for 3 seconds.
4. Within 5 seconds after the safety belt warning indicator turns off, at a moderate speed, buckle
then unbuckle the safety belt.
- This disables the Belt-Minder(R) feature for that seating position, if it is currently enabled. As
confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds.
- This enables the Belt-Minder(R) feature for that seating position, if it is currently disabled. As
confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds followed by
a second flash sequence after a brief pause.
5. After confirmation, the deactivation/activation procedure is complete.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Description and Operation
Seat Belt Retractor: Description and Operation
Safety Belt System
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, 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.
When replacing any active occupant restraint components, use only the replacement parts
specified in the Ford Customer Service Division Master Parts and Accessories Catalog.
Safety Belt Retractors
- Adaptive load limiting retractor (front only)
- Dual locking mode Emergency Locking Retractor (ELR)
- Automatic Locking Retractor (ALR) (all except driver seat)
Adaptive load limiting
Adaptive load limiting safety belt retractors are pyrotechnic devices integrated with the driver and
front passenger safety belt retractor assemblies. Adaptive load limiting safety belt 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 safety belt retractor. The RCM uses this information and all other information
provided by the restraints system to determine what action is to be taken.
For adaptive load limiting safety belt retractor diagnostic information, refer to Diagnosis and Testing
in Air Bag Systems. See: Air Bag Systems/Testing and Inspection
Automatic Locking Retractor (ALR)
The ALR mode is used when locking a child seat in an outboard seating position. The ALR mode is
automatically activated when the safety belt webbing is fully extracted from the retractor and then
allowed to retract. As the safety belt webbing is retracted back onto the spool, an audible clicking
sound is made indicating the safety belt retractor is in ALR mode and the safety belt webbing will
not pull back out of the safety belt retractor. To disengage the ALR mode, allow the safety belt
webbing to fully retract back onto the spool. The ALR mode is disengaged when the webbing is
free to extract and retract back into the retractor. For testing, refer to the appropriate Functional
Test procedure Diagnosis and Testing in Safety Belt System See: Testing and
Inspection/Component Tests and General Diagnostics.
Emergency Locking Retractor (ELR)
The ELR is a vehicle-sensitive feature designed to activate and lock the safety belt webbing during
hard braking, hard cornering or in an impact of approximately 24 km/h (15 mph). The ELR feature
helps to reduce the forward movement of the driver and passengers. For testing, refer to the
appropriate Functional Test procedure Diagnosis and Testing in Safety Belt System See: Testing
and Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Testing and Inspection > Functional Test - Safety Belt Retractor
Seat Belt Retractor: Testing and Inspection Functional Test - Safety Belt Retractor
Safety Belt System
Component Test
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, 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.
Carry out the appropriate Functional Test(s) as determined in Inspection and Verification.
Functional Test - Safety Belt Retractor
The safety belt retractor 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 safety belt retractor operates without excessive effort or binding.
3. Install a new safety belt retractor if any concern is found or the complaint has been verified.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Testing and Inspection > Functional Test - Safety Belt Retractor > Page 6385
Seat Belt Retractor: Testing and Inspection Functional Test - Safety Belt Retractor, Automatic
Locking Retractor (ALR) Mode
Safety Belt System
Component Test
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, 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.
Carry out the appropriate Functional Test(s) as determined in Inspection and Verification.
Functional Test - Safety Belt Retractor, Automatic Locking Retractor (ALR) Mode
1. Position the seat backrest fully upright (if adjustable).
2. Position the safety belt shoulder height adjuster (if equipped) in the full down or up position.
3. Fasten the safety belt.
4. Pull out the safety belt webbing until the Automatic Locking Retractor (ALR) feature is activated.
5. Allow the safety belt webbing to retract until it stops.
6. Pull on the safety belt webbing to check that the safety belt retractor has remained in the ALR
mode. If the safety belt retractor is not locked,
install a new safety belt retractor.
7. Unfasten the safety belt and allow the safety belt webbing to retract to its stowed position.
8. Pull out and retract the safety belt webbing to verify the safety belt retractor has converted
automatically out of ALR mode. If the safety belt
retractor remains locked in the ALR mode, install a new safety belt retractor.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Testing and Inspection > Functional Test - Safety Belt Retractor > Page 6386
Seat Belt Retractor: Testing and Inspection Functional Test - Safety Belt Retractor, Road Test
Inspection
Safety Belt System
Component Test
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, 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.
Carry out the appropriate Functional Test(s) as determined in Inspection and Verification.
Functional Test - Safety Belt Retractor, Road Test Inspection
WARNING: The driver and passenger must be prepared to brace themselves in the event the
safety belt retractor does not lock. Failure to follow this instruction may result in serious personal
injury.
NOTE: Make sure there is no excessive slack in the safety belt webbing across the torso during
testing.
NOTE: Do not jerk on the safety belt webbing when carrying out this test.
1. Test the safety belts in the following sequence:
1. Fasten the safety belts and proceed to a safe area.
2. Attain a speed of 24 km/h (15 mph).
3. WARNING: Apply maximum brake force only on dry concrete or equivalent hard surface,
NEVER on wet pavement or gravel.
Failure to follow this instruction may result in serious personal injury.
Grasp the shoulder harness, lean forward and apply the brakes, making a maximum braking
application without a skid.
4. The safety belts should lock up with minimum webbing extension.
5. If there is a lockup of all safety belt retractors being tested, the safety belt retractors are
functioning correctly. If any safety belt retractor fails
to lock up, install a new safety belt retractor(s).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
- 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, 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 6389
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
NOTE: 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 Supplemental Restraint System (SRS). For additional information, refer to
Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures portion of Air Bag Systems.
3. Remove the safety belt anchor cover.
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 lower B-pillar trim panel.
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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
12. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and
Repowering in the General Procedures portion of Air Bag Systems.
13. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System See: Testing and Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 6390
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, 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 second row, 40 percent seat.
2. Remove the bolt and safety belt anchor.
- To install tighten to 121 Nm (89 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 6391
3. NOTE: LH shown, RH similar.
Remove the 4 screws and position aside the latch covers.
4. Remove the safety belt guide cover.
5. If equipped, remove the 3 screws and the upper latch cover.
6. Release the J-clip at the bottom of the seat backrest.
7. Remove all the staples in the backrest support panel.
8. NOTICE: 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.
9. Position aside the backrest foam pad.
10. Remove the safety belt retractor cover.
11. Remove the bolt and safety belt retractor.
- To install, tighten to 75 Nm (55 lb-ft).
12. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
13. Check the active restraint system for correct operation. For additional information, refer to
Safety Belt System See: Testing and
Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 6392
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)
- 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, 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 (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 6393
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. NOTICE: 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. 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
11. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System See: Testing and Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 6394
Seat Belt Retractor: Service and Repair Safety Belt Retractor - Second Row, Outboard
Safety Belt Retractor - Second Row, Outboard
Explorer/Mountaineer
Explorer Sport Trac
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 6395
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, 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 seat.
Explorer Sport Trac
2. Remove the trim panels.
Explorer/Mountaineer with 60/40 E-Z entry seat
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 6396
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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
11. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System See: Testing and Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 6397
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)
- 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, 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 quarter trim panel.
2. Remove the bolt and D-ring.
- To install, tighten to 40 Nm (30 lb-ft).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 6398
3. Remove the bolt and safety belt retractor.
- To install, tighten to 40 Nm (30 lb-ft).
4. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
5. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System See: Testing and Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Driver Safety Belt Retractor Pretensioner
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Driver Safety Belt Retractor Pretensioner > Page 6403
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Driver Safety Belt Retractor Pretensioner > Page 6404
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Driver Safety Belt Retractor Pretensioner > Page 6405
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Driver Safety Belt Retractor Pretensioner > Page 6406
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Page 6407
Seat Belt Tensioner: Description and Operation
Safety Belt System
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, 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.
When replacing any active occupant restraint components, use only the replacement parts
specified in the Ford Customer Service Division Master Parts and Accessories Catalog.
Safety Belt Retractors
- Adaptive load limiting retractor (front only)
- Dual locking mode Emergency Locking Retractor (ELR)
- Automatic Locking Retractor (ALR) (all except driver seat)
Adaptive load limiting
Adaptive load limiting safety belt retractors are pyrotechnic devices integrated with the driver and
front passenger safety belt retractor assemblies. Adaptive load limiting safety belt 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 safety belt retractor. The RCM uses this information and all other information
provided by the restraints system to determine what action is to be taken.
For adaptive load limiting safety belt retractor diagnostic information, refer to Diagnosis and Testing
in Air Bag Systems. See: Air Bag Systems/Testing and Inspection
Automatic Locking Retractor (ALR)
The ALR mode is used when locking a child seat in an outboard seating position. The ALR mode is
automatically activated when the safety belt webbing is fully extracted from the retractor and then
allowed to retract. As the safety belt webbing is retracted back onto the spool, an audible clicking
sound is made indicating the safety belt retractor is in ALR mode and the safety belt webbing will
not pull back out of the safety belt retractor. To disengage the ALR mode, allow the safety belt
webbing to fully retract back onto the spool. The ALR mode is disengaged when the webbing is
free to extract and retract back into the retractor. For testing, refer to the appropriate Functional
Test procedure Diagnosis and Testing in Safety Belt System See: Testing and
Inspection/Component Tests and General Diagnostics.
Emergency Locking Retractor (ELR)
The ELR is a vehicle-sensitive feature designed to activate and lock the safety belt webbing during
hard braking, hard cornering or in an impact of approximately 24 km/h (15 mph). The ELR feature
helps to reduce the forward movement of the driver and passengers. For testing, refer to the
appropriate Functional Test procedure Diagnosis and Testing in Safety Belt System See: Testing
and Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Locations > Page 6411
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor
Impact Sensor: Locations RH Front Impact Severity Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6417
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6418
Impact Sensor: Locations LH Front Impact Severity Sensor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6419
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6420
Impact Sensor: Locations Side Impact Sensor, Second Row Driver Side
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6421
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6422
Impact Sensor: Locations Side Impact Sensor, Second Row Passenger Side
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6423
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6424
Impact Sensor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6425
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6426
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6427
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6428
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6429
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6430
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6431
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6432
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > RH Front Impact Severity Sensor > Page 6433
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Side Impact Sensor, First Row Driver Side
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6436
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6437
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6438
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6439
Impact Sensor: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6440
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6441
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front Impact Severity Sensor
Impact Sensor: Service and Repair Front Impact Severity Sensor
Front Impact Severity Sensor
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag
Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System
(SRS) Depowering and Repowering in the General Procedures.
2. Remove the 4 pin-type retainers and 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 front impact severity sensor. To install, tighten to 12 Nm (106 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front Impact Severity Sensor > Page 6444
5. To install, reverse the removal procedure.
6. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag
Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System
(SRS) Depowering and Repowering in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front Impact Severity Sensor > Page 6445
Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar
Side Impact Sensor - C-Pillar, Explorer, Mountaineer
NOTE: RH shown, LH similar.
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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
NOTE: The LH and RH C-pillar mounted side impact sensors are not interchangeable.
1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag
Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System
(SRS) Depowering and Repowering in the General Procedures.
2. Remove the rear door scuff plate.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front Impact Severity Sensor > Page 6446
NOTE: 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 (106 lb-in).
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. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag
Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System
(SRS) Depowering and Repowering in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front Impact Severity Sensor > Page 6447
Impact Sensor: Service and Repair Side Impact Sensor - Front Door
Side Impact Sensor - Front Door
NOTE: LH side shown, RH similar.
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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag
Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System
(SRS) Depowering and Repowering in the General Procedures.
2. Remove the front interior door trim panel.
3. Detach the rearward lower corner of the weathershield on the door to access the side impact
sensor (pressure sensor).
4. Disconnect the electrical connector.
5. Remove the bolt and 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. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag
Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System
(SRS) Depowering and Repowering in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations > Safety Belt Buckle Switch, Passenger
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 6452
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Safety Belt Buckle Switch, Driver
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 6455
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > OCS Rail 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > OCS Rail 1 > Page 6460
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 6461
Seat Occupant Sensor: Service and Repair
Occupant Classification Sensor
NOTE: Outboard Occupant Classification Sensor (OCS) rail shown, inboard similar.
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.
WARNING: 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.
WARNING: 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.
WARNING: 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 6462
crash.
NOTICE: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Remove the front passenger seat.
2. NOTICE: 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 Occupant Classification Sensor (OCS) rail position, electrical wiring routing, wiring,
connector and wiring retainers for installation.
On the affected side, detach the 2 OCS rail wiring retainers and using a suitable tool, release the
tab and disconnect the OCS rail electrical connector.
3. If equipped, disconnect the power seat track motor electrical connector.
4. Move the seat to the forward stop position.
- If equipped with a power seat track, apply power and ground to the pins shown.
5. Remove the 2 rear bolts from the OCS rail.
6. Move the seat to the rearward stop position.
- If equipped with a power seat track, apply power and ground to the pins shown.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 6463
7. NOTE: Note the locator tab position where the OCS rail goes through the rail shield and into the
rear seat track mounting point for installation.
Remove the 2 front bolts and OCS rail and shield.
Installation
NOTE: If installing a new seat track, position the seat track where the seat will be in the full
rearward position before installing the OCS rails.
NOTE: 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.
NOTICE: 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: Make sure the OCS rail shield is seated correctly on the OCS rail.
Install the shield on the OCS rail, and install the OCS rail and shield on the seat track with the
locator tab aligned correctly as shown.
2. Hold the OCS rail and shield firmly in position and install the front mounting position rear bolt.
- Tighten to 25 Nm (18 lb-ft).
3. Hold the OCS rail and shield firmly in position and install the front mounting position front bolt.
- Tighten to 25 Nm (18 lb-ft).
4. Move the seat to the forward stop position.
- If equipped with a power seat track, apply power and ground to the pins shown.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 6464
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, route the 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 component, carry out the Occupant Classification Sensor
(OCS) System Zero Seat Weight Test and prove out the SRS. For additional information, refer to
Occupant Classification Sensor (OCS) System Zero Seat Weight Test See: Air Bag
Systems/Testing and Inspection/Component Tests and General Diagnostics.
- If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS)
System Reset procedure and prove out the SRS. For additional information, refer to Occupant
Classification Sensor (OCS) System Reset See: Air Bag Systems/Service and Repair/Occupant
Classification Sensor (OCS) System Reset.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
NOTE: Power seat shown, manual seat similar.
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.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Position the front seat to the rearmost and upward position.
2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag
Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System
(SRS) Depowering and Repowering in the General Procedures.
3. Disconnect the seat position sensor 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.
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. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Air Bag
Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System
(SRS) Depowering and Repowering in the General Procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Page 6471
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations > Page 6477
Accessory Delay Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations > Page 6478
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Antenna Cable - Satellite Radio
Antenna Cable: Service and Repair Antenna Cable - Satellite Radio
Antenna Cable - Satellite Radio
Vehicles Without Navigation
NOTE: Instrument panel shown removed for clarity.
Vehicles With Navigation
NOTE: Glove compartment shown removed for clarity.
Removal and Installation
NOTE: Vehicles without navigation only have an upper satellite radio antenna cable.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Antenna Cable - Satellite Radio > Page 6485
Lower cable (vehicles with navigation)
NOTE: The lower satellite antenna cable is only serviceable by cutting the ends off the existing
antenna cable and taping them to prevent NVH concerns. The new cable should be overlaid on the
electrical harness and secured, as necessary.
1. Remove the Audio Control Module (ACM). For additional information, refer to Audio Control
Module (ACM) See: Cellular
Phone/Communications Control Module/Service and Repair/Removal and Replacement/Audio
Control Module (ACM).
Upper cable (all vehicles)
2. Remove the RH A-pillar trim panel.
3. Disconnect the satellite antenna electrical connector.
Both cables
4. NOTE: Lower the glove compartment completely to access the connection.
Disconnect the upper satellite radio antenna cable from the Satellite Digital Audio Receiver System
(SDARS) module (vehicles without navigation) or the lower satellite radio antenna cable (vehicles
with navigation).
5. Remove the satellite radio antenna cable.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Antenna Cable - Satellite Radio > Page 6486
Antenna Cable: Service and Repair Antenna Lead-In Cable
Antenna Lead-In Cable
Removal and Installation
1. Remove the Audio Control Module (ACM). For additional information, refer to Audio Control
Module (ACM) See: Cellular
Phone/Communications Control Module/Service and Repair/Removal and Replacement/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 (V6-4.0L (2009))
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 Passive Anti-Theft System (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.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Locations > Page 6498
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Locations > Page 6499
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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Locations > Page 6500
Keyless Entry Key-Pad: Service and Repair
Keyless Entry Keypad
Removal and Installation
1. Position the front window glass to the full down position.
2. Position the door glass top run aside to access the door pillar trim panel screws.
3. Remove the 3 door pillar trim panel screws and the door pillar trim panel.
4. Disconnect the electrical connector and remove the keyless entry keypad from the door pillar
trim panel.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter
Programming
Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry (RKE) Transmitter
Programming
Remote Keyless Entry (RKE) Transmitter Programming
NOTE: All Remote Keyless Entry (RKE) transmitters must be programmed at the same time.
NOTE: 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 the 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 Locks, Latches and Entry Systems See: Body and Frame/Locks/Power Locks/Testing and
Inspection. Make sure that no more than the maximum number of 6 RKE transmitters are
attempted to be programmed.
5. Exiting the programming mode is accomplished if one of the following occurs:
- The key transitions to the OFF position.
- Twenty seconds have passed since entering programming mode or since the last RKE transmitter
was programmed.
- The maximum number of 6 RKE transmitters have been programmed.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter
Programming > Page 6505
Keyless Entry Transmitter: Testing and Inspection Autolock and Auto-Unlock Programming
Autolock and Auto-Unlock 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter
Programming > Page 6506
Within 5 seconds of Step 3, release the 3/4 button on the keyless entry keypad.
Auto-Unlock Programming Using the Ignition Lock Cylinder
1. Close all doors and windows.
2. Confirm that the ignition key is OFF.
3. NOTE: Steps 5 through 9 must be carried out within 30 seconds.
Turn the ignition key from OFF to RUN.
4. Press the door lock control switch UNLOCK button 3 times.
5. Turn the ignition key from RUN to OFF.
6. Press the door lock control switch UNLOCK button 3 times.
7. Turn the ignition key from OFF to RUN.
8. Verify the horn chirps. This indicates the enable/disable mode and now is ready to accept
program changes.
9. Press the door lock control switch LOCK button then the UNLOCK button 1 time to command the
module to toggle the auto-unlock feature.
10. Verify that the horn chirps. There should be 1 chirp indicating that auto-unlock feature has been
disabled. If 1 chirp is heard, followed by a longer
sound of the horn, the auto-unlock feature has just been enabled.
11. Turn the key to the OFF position or wait 2 minutes to exit the enable/disable mode.
12. Verify that the horn chirps once to indicate that a feature has been changed and that
auto-unlock has been toggled.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter
Programming > Page 6507
Keyless Entry Transmitter: Testing and Inspection 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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter
Programming > Page 6508
Keyless Entry Transmitter: Testing and Inspection Remote Memory Deactivation
Remote Memory Deactivation
1. Press the set button on the lower center of the instrument panel.
2. Within 5 seconds press one control on the Remote Keyless Entry (RKE) transmitter and then the
set button on the lower center of the instrument
panel to associate the RKE transmitter to the driver 1 or the driver 2 position.
3. If a second memory setting is desired to be deactivated, repeat the procedure with the second
RKE transmitter.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter
Programming > Page 6509
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6519
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 6520
^ 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 (V6-4.0L (2009))
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 6521
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 (V6-4.0L (2009))
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 6522
^ 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 (V6-4.0L (2009))
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 6523
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6524
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 (V6-4.0L (2009))
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 6525
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 (V6-4.0L (2009))
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 6526
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 (V6-4.0L (2009))
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 6527
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6532
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 (V6-4.0L (2009))
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 6533
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 (V6-4.0L (2009))
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 6534
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 (V6-4.0L (2009))
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 6535
^ 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 (V6-4.0L (2009))
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 6536
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 (V6-4.0L (2009))
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 6537
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 (V6-4.0L (2009))
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 6538
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 (V6-4.0L (2009))
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 6539
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 (V6-4.0L (2009))
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 6540
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 (V6-4.0L (2009))
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 6541
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 (V6-4.0L (2009))
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 6542
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6548
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.
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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.
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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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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.
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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
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10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6555
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.
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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 (V6-4.0L (2009))
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.
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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 (V6-4.0L (2009))
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09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6562
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 (V6-4.0L (2009))
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 6563
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 (V6-4.0L (2009))
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 6564
^ 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 (V6-4.0L (2009))
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 6565
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 (V6-4.0L (2009))
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 6566
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 (V6-4.0L (2009))
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 6567
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 (V6-4.0L (2009))
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 6568
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 (V6-4.0L (2009))
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 6569
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 (V6-4.0L (2009))
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 6570
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 (V6-4.0L (2009))
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 6571
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6584
^ 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 (V6-4.0L (2009))
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 6585
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6590
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 (V6-4.0L (2009))
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 6591
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6601
^ 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 (V6-4.0L (2009))
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 6602
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6607
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 (V6-4.0L (2009))
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 6608
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 (V6-4.0L (2009))
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: >
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 (V6-4.0L (2009))
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: >
10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 6614
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 (V6-4.0L (2009))
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: >
10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 6620
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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Locations > Accessory Protocol Interface Module (APIM)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Locations > Accessory Protocol Interface Module (APIM) > Page 6623
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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)
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6626
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6627
Communications Control Module: Diagrams Audio Control Module (ACM)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6628
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6629
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Service and Repair > Procedures
Communications Control Module: Procedures
Accessory Protocol Interface Module (APIM) Software Level Check
Accessory Protocol Interface Module (APIM) Software Level Check
NOTE: This procedure applies to checking the Accessory Protocol Interface Module (APIM)
software level. To program the APIM, refer to Accessory Protocol Interface Module (APIM)
Programming in Information Bus. See: Powertrain Management/Computers and Control
Systems/Information Bus/Testing and Inspection/Programming and Relearning/Accessory Protocol
Interface Module (APIM) Programming
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 software level.
- The display shows both the Vehicle Interface Processor (VIP) and Consumer Interface Processor
(CIP) software levels.
8. The scan tool displays the following information:
- Last Recorded State - Hardware VIN: vehicle identification number associated with the current APIM
- Installed date: date the APIM was installed
- Radio: currently identified ACM in the vehicle
- HW Part No.: APIM hardware part number
- Un-installed date: date (if any) the APIM was uninstalled
- S/N: APIM serial number
- Last Recorded State - Software Date/Time: date and time of last recorded software installation
- VIP: VIP software that was installed at that time
- CIP: CIP software that was installed at that time
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Service and Repair > Procedures > Page 6632
- Description: a description of the content of the software revision
- History - Software Date/Time: date and time of any recorded software installation
- VIP: VIP software that was installed at that time
- CIP: CIP software that was installed at that time
- Description: a description of the content of the software revision
- Available Software for Programming Select: allows the software package to be selected
- Lineage: the original software release, if the software available is a revision
- VIP: VIP software level that is available with the selection
- CIP: CIP software level that is available with the selection
- Description: a description of the content of the software revision
9. Click a CIP software level to view the device compatibility list associated with the CIP software
level, if desired.
10. To exit the APIM software level check, disconnect the scan tool from the DLC and the USB
port, or exit the OASIS screen.
Audio Control Module (ACM) Self-Diagnostic Mode
Audio Control Module (ACM) Self-Diagnostic Mode
Audio Systems Without Navigation
1. Turn the Audio Control Module (ACM) on.
2. Operate the audio system in radio tuner (AM/FM) mode.
3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins.
- The display indicates each speaker as it is tested.
4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after Step
3 by turning the ACM off.
Before the speaker walk test is complete, carry out any of the following actions:
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Service and Repair > Procedures > Page 6633
5. To exit the self-diagnostic mode, turn the ACM off.
Satellite Digital Audio Receiver System (SDARS) Module Electronic Serial Number (ESN) Retrieval
- Vehicles Without Navigation
1. Operate the audio system in satellite radio mode.
2. Press and hold the AUX button and preset button 1, simultaneously.
- The Satellite Digital Audio Receiver System (SDARS) module Electronic Serial Number (ESN)
displays on the screen.
3. Record the SDARS module ESN.
4. Turn the audio system off.
Audio Systems With Navigation
1. Turn the Audio Control Module (ACM) on.
2. Operate the audio system in radio tuner (AM/FM) mode.
3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins.
- The display indicates each speaker as it is tested.
4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after this
step, or by allowing the speaker walk test to
complete on its own.
Before the speaker walk test is complete, press the "End Test" selection.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Service and Repair > Procedures > Page 6634
5. The following tests are available through the "BEZEL DIAGNOSTICS" menu:
6. To exit the self-diagnostic mode, press the "Exit Diagnostics" selection from the "BEZEL
DIAGNOSTICS" menu.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Service and Repair > Procedures > Page 6635
Communications Control Module: Removal and Replacement
Audio Control Module (ACM)
Audio Control Module (ACM)
Removal and Installation
NOTE: It is not necessary to remove the Audio Control Module (ACM) to retrieve the part number.
For additional information, refer to Audio Control Module (ACM) Self-Diagnostic Mode See:
Procedures/Audio Control Module (ACM) Self-Diagnostic Mode.
1. NOTE: Module configuration is required when a new ACM is being installed.
Upload the ACM configuration information to the scan tool.
2. Remove the instrument panel center finish panel.
3. Remove the 4 screws and the ACM.
- Disconnect the ACM electrical connectors.
4. To install, reverse the removal procedure.
- Download the configuration information to the ACM.
Accessory Protocol Interface Module (APIM)
Accessory Protocol Interface Module (APIM)
Floor Console Components
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Service and Repair > Procedures > Page 6636
Accessory Protocol Interface Module (APIM)
Removal and Installation
1. NOTE: It is necessary to record the current Accessory Protocol Interface Module (APIM)
software and hardware level when a new APIM is being
installed to make sure that the new component is the same version as the component being
replaced.
Retrieve and record the current APIM software and hardware level. For additional information, refer
to Accessory Protocol Interface Module (APIM) Software Level Check See: Procedures/Accessory
Protocol Interface Module (APIM) Software Level Check.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Service and Repair > Procedures > Page 6637
2. Remove the 4 screws and the front floor console stowage door.
3. Remove the 2 screws and the front floor console rear trim panel.
- Pull straight back to disengage the clips.
4. Remove the 2 screws and the front floor console finish panel.
- Pull straight up to disengage the clips.
5. Remove the front floor console stowage bin.
- Remove the 4 screws.
- Disconnect the audio input jack electrical connector.
- Disconnect the Universal Serial Bus (USB) port electrical connector.
- Disconnect the APIM electrical connector.
- Disconnect the USB cable electrical connector (at the APIM).
6. Remove the 4 screws and the APIM.
7. To install, reverse the removal procedure.
- If a new APIM is being installed, program the APIM to the correct software level.
Universal Serial Bus (USB) Cable and Port
Universal Serial Bus (USB) Cable and Port
Floor Console Components
Universal Serial Bus (USB) Cable And Port-To-Bezel
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Service and Repair > Procedures > Page 6638
USB Cable And Port-To-Accessory Protocol Interface Module (APIM)
Removal and Installation
1. Remove the 4 screws and the front floor console stowage door.
2. Remove the 2 screws and the front floor console rear trim panel.
- Pull straight back to disengage the clips.
3. Remove the 2 screws and the front floor console finish panel.
- Pull straight up to disengage the clips.
4. Using a suitable tool (such as a trim removal tool) pry the audio input jack bezel from the storage
bin.
- Disconnect the audio input jack electrical connector.
5. Disconnect the Universal Serial Bus (USB) port connector from the audio input jack bezel.
6. Remove the 4 screws and the front floor console stowage bin.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Service and Repair > Procedures > Page 6639
7. Remove the USB cable and port.
- Disconnect the electrical connector.
8. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations
Parking Assist Control Module: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations > Page 6644
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations > Page 6645
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations > Page 6646
Parking Assist Control Module: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations > Page 6647
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations > Page 6648
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations > Page 6649
Parking Assist Control Module: Service and Repair
Parking Aid Module (PAM) - Explorer
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 bolts.
6. Remove the PAM assembly.
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left
Parking Assist Distance Sensor: Locations Parking Aid Sensor, Outer Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6654
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6655
Parking Assist Distance Sensor: Locations Parking Aid Sensor, Outer Right
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6656
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6657
Parking Assist Distance Sensor: Locations Parking Aid Sensor, Inner Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6658
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6659
Parking Assist Distance Sensor: Locations Parking Aid Sensor, Inner Right
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6660
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6663
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6664
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6665
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Warning Indicator > Component Information > Diagrams > Page 6669
Parking Assist Warning Indicator: Service and Repair
Parking Aid Speaker
Removal and Installation
1. Remove the LH C-pillar trim panel.
2. Remove the bolt and the speaker and bracket assembly.
- Disconnect the electrical connector.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations > Page 6673
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Service and Repair > Reset Procedure
Driver/Vehicle Information Display: Reset Procedure
Message Center Configuration
Oil Life Reset And Start Value - With Message Center
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 - Without Message Center
NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180
days.
NOTE: All message center functions are carried out using the single stem reset button in the
Instrument Cluster (IC).
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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Service and Repair > Reset Procedure > Page 6676
Driver/Vehicle Information Display: Removal and Replacement
Message Center Switch
Removal and Installation
1. Remove the instrument panel center finish panel.
2. Press the retaining tabs and remove the message center switch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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
> Page 6685
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 (V6-4.0L (2009))
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
> Page 6686
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6691
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 (V6-4.0L (2009))
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 6692
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 (V6-4.0L (2009))
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 6693
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 (V6-4.0L (2009))
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 6694
^ 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 > Emergency Contact Module > Component Information >
Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality
> Page 6695
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 (V6-4.0L (2009))
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 6696
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 (V6-4.0L (2009))
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 6697
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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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 6698
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 (V6-4.0L (2009))
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 6699
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 (V6-4.0L (2009))
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 6700
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 (V6-4.0L (2009))
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 6701
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6707
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 (V6-4.0L (2009))
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 6708
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 (V6-4.0L (2009))
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.
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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 6713
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 (V6-4.0L (2009))
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 6714
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 (V6-4.0L (2009))
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 6715
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 (V6-4.0L (2009))
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 6716
^ 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 (V6-4.0L (2009))
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 6717
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 (V6-4.0L (2009))
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 6718
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 (V6-4.0L (2009))
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 6719
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 (V6-4.0L (2009))
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 6720
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 (V6-4.0L (2009))
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 6721
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 (V6-4.0L (2009))
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 6722
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 (V6-4.0L (2009))
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 6723
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6728
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 (V6-4.0L (2009))
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 6729
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6735
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 (V6-4.0L (2009))
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 6736
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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack,
Entertainment System > Component Information > Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack,
Entertainment System > Component Information > Diagrams > Page 6741
Auxiliary Input / Output Jack: Service and Repair
Audio Input Jack
Removal and Installation
1. Remove the floor console finish panel.
2. Release the tabs and remove the audio input jack.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control
Module > Component Information > Technical Service Bulletins > Page 6755
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control
Module > Component Information > Technical Service Bulletins > Page 6756
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: Module configuration is required when a new Rear Entertainment Module (RETM) is being
installed.
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 (such as a flat-bladed screwdriver), 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control
Panel > Component Information > Service and Repair > Page 6760
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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Locations > Page 6764
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Locations > Page 6765
Garage Door Opener Transmitter: Description and Operation
Universal Transmitter
Vehicles With Roof Opening Panel and Auxiliary A/C
The universal transmitter is an integral part of the LH sun visor.
All Other Vehicles
The universal transmitter is an integral part of the overhead console.
The universal transmitter provides a convenient way to substitute up to 3 hand-held transmitters
with a single built-in device. The universal transmitter can learn the radio frequency codes of most
current transmitters. The universal transmitter:
- operates garage doors, gates and home/office lighting and security systems.
- learns and transmits the radio frequency of up to 3 hand-held transmitters from any of the
systems mentioned above.
- is powered by the vehicle battery and charging system.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Special Tools Used With Diagnostics
Universal Transmitter
Inspection And Verification
Universal Transmitter
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of 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. 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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6768
Garage Door Opener Transmitter: Symptom Related Diagnostic Procedures
Universal Transmitter
Symptom Chart
Symptom Chart
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6769
Garage Door Opener Transmitter: Pinpoint Tests
Universal Transmitter
Pinpoint Tests
Pinpoint Test A: The Universal Transmitter Is Inoperative
Refer to Wiring Diagram Set 89, Interior Lamps for schematic and connector information. See:
Diagrams/Electrical Diagrams/Diagrams By Number
Normal Operation
Vehicles with roof opening panel and auxiliary A/C will have the universal transmitter located as an
integral part of the LH sun visor. For all other vehicles, 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
PINPOINT TEST A: THE UNIVERSAL TRANSMITTER IS INOPERATIVE
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- A1 CHECK THE UNIVERSAL TRANSMITTER
- Press any of the buttons on the universal transmitter.
Does the universal transmitter LED illuminate?
Yes
GO to A2.
No
GO to A3.
------------------------------------------------- A2 PROGRAM A HAND-HELD TRANSMITTER INTO THE
UNIVERSAL TRANSMITTER
- Program the universal transmitter. Refer to Universal Transmitter Programming See:
Programming and Relearning.
- Does the universal transmitter program successfully?
Yes
The universal transmitter is OK. VERIFY the receiver operates correctly.
No
INSTALL a new universal transmitter. For vehicles with roof opening panel and auxiliary A/C,
REFER to Headliner in Headliner.
For all other vehicles, REFER to Overhead Console in Console. TEST the system for normal
operation.
------------------------------------------------- A3 CHECK CIRCUIT CLN01 (GN/VT) FOR AN OPEN
- Ignition OFF.
- Disconnect: LH Vanity Mirror Lamp C907 (with roof opening panel and auxiliary A/C) or Universal
Transmitter C928 (all other vehicles).
- Ignition ON.
- Measure the voltage between the universal transmitter C907-1 (with roof opening panel and
auxiliary A/C) or C928-2 (all other vehicles), circuit CLN01 (GN/VT), harness side and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6770
- Is the voltage greater than 10 volts?
Yes
GO to A4.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- A4 CHECK CIRCUIT GD133 (BK) FOR AN OPEN
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the universal transmitter C907-2 (with roof opening panel and
auxiliary A/C) or C928-1 (all other vehicles), circuit GD133 (BK), harness side and ground.
- Is the resistance less than 5 ohms?
Yes
INSTALL a new universal transmitter. For vehicles with roof opening panel and auxiliary A/C,
REFER to Headliner in Headliner.
For all other vehicles, REFER to Overhead Console in Console. TEST the system for normal
operation.
No
REPAIR the circuit. TEST the system for normal operation.
-------------------------------------------------
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6771
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6781
^ 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 (V6-4.0L (2009))
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 6782
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6788
^ 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 (V6-4.0L (2009))
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 6789
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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Locations > Page 6794
Memory Positioning Module: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Locations > Page 6795
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Locations > Page 6796
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Locations > Page 6797
Memory Positioning Module: Service and Repair
Driver Seat Module (DSM)
Removal and Installation
NOTICE: 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 Driver Seat Module
(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: When a new DSM is installed, it is necessary to download the module configuration
information from the scan tool into the new DSM.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Locations > Page 6798
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch >
Component Information > Locations > Page 6802
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > 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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > 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 6812
^ 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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > 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 6813
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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > 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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > 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 6819
^ 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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > 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 6820
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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor >
Component Information > Locations
Pedal Positioning Motor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor >
Component Information > Locations > Page 6825
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor >
Component Information > Locations > Page 6826
Pedal Positioning Motor: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch >
Component Information > Locations > Page 6830
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Diagrams > Subwoofer Amplifier
Amplifier: Diagrams Subwoofer Amplifier
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Diagrams > Subwoofer Amplifier > Page 6836
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Diagrams > Subwoofer Amplifier > Page 6837
Amplifier: Diagrams Audio Amplifier
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Diagrams > Subwoofer Amplifier > Page 6838
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Diagrams > Page 6839
Amplifier: Service and Repair
Audio Amplifier
NOTE: Glove compartment shown removed for clarity.
Removal and Installation
1. Remove the RH cowl side trim panel.
2. NOTE: Lower the glove compartment door to access the top nut.
Remove the bolt, the nut, and the audio amplifier.
- Disconnect the electrical connectors.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Remote Switch, Audio - Stereo > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Remote Switch, Audio - Stereo > Component Information > Locations > Page 6857
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
NOTE: When removing the steering wheel controls, disengage the RH side of the controls first.
Using a suitable tool (such as a trim removal tool), pry the steering wheel controls out of the
steering wheel.
2. NOTE: Do not allow the electrical connector to fall back into the steering wheel.
Remove the steering wheel controls.
- Disconnect the electrical connector.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6869
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6875
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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Speaker, Left Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Speaker, Left Front > Page 6878
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Speaker, Left Front > Page 6879
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Speaker, Left Front > Page 6880
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Speaker - Door
Speaker: Service and Repair Speaker - Door
Speaker - Door
NOTE: RH front shown, others similar.
Removal and Installation
1. Remove the door trim panel.
2. Remove the 4 screws and the door speaker.
- Disconnect the electrical connector.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Speaker - Door > Page 6883
Speaker: Service and Repair Subwoofer Speaker
Subwoofer Speaker - Explorer, Mountaineer
Removal and Installation
1. Remove the RH rear quarter trim panel.
2. Disconnect the electrical connector.
3. Remove the bolt, the 2 nuts and the subwoofer enclosure.
- To install, tighten the bolt to 5 Nm (44 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 6889
Accessory Delay Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 6890
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6903
^ 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 (V6-4.0L (2009))
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 6904
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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
6909
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 (V6-4.0L (2009))
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
6910
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6920
^ 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 (V6-4.0L (2009))
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 6921
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6926
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 (V6-4.0L (2009))
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 6927
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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module
(APIM)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module
(APIM) > Page 6930
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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)
Part 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6933
Part 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6934
Communications Control Module: Diagrams Audio Control Module (ACM)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6935
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6936
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Service and Repair > Procedures
Communications Control Module: Procedures
Accessory Protocol Interface Module (APIM) Software Level Check
Accessory Protocol Interface Module (APIM) Software Level Check
NOTE: This procedure applies to checking the Accessory Protocol Interface Module (APIM)
software level. To program the APIM, refer to Accessory Protocol Interface Module (APIM)
Programming in Information Bus. See: Powertrain Management/Computers and Control
Systems/Information Bus/Testing and Inspection/Programming and Relearning/Accessory Protocol
Interface Module (APIM) Programming
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 software level.
- The display shows both the Vehicle Interface Processor (VIP) and Consumer Interface Processor
(CIP) software levels.
8. The scan tool displays the following information:
- Last Recorded State - Hardware VIN: vehicle identification number associated with the current APIM
- Installed date: date the APIM was installed
- Radio: currently identified ACM in the vehicle
- HW Part No.: APIM hardware part number
- Un-installed date: date (if any) the APIM was uninstalled
- S/N: APIM serial number
- Last Recorded State - Software Date/Time: date and time of last recorded software installation
- VIP: VIP software that was installed at that time
- CIP: CIP software that was installed at that time
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6939
- Description: a description of the content of the software revision
- History - Software Date/Time: date and time of any recorded software installation
- VIP: VIP software that was installed at that time
- CIP: CIP software that was installed at that time
- Description: a description of the content of the software revision
- Available Software for Programming Select: allows the software package to be selected
- Lineage: the original software release, if the software available is a revision
- VIP: VIP software level that is available with the selection
- CIP: CIP software level that is available with the selection
- Description: a description of the content of the software revision
9. Click a CIP software level to view the device compatibility list associated with the CIP software
level, if desired.
10. To exit the APIM software level check, disconnect the scan tool from the DLC and the USB
port, or exit the OASIS screen.
Audio Control Module (ACM) Self-Diagnostic Mode
Audio Control Module (ACM) Self-Diagnostic Mode
Audio Systems Without Navigation
1. Turn the Audio Control Module (ACM) on.
2. Operate the audio system in radio tuner (AM/FM) mode.
3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins.
- The display indicates each speaker as it is tested.
4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after Step
3 by turning the ACM off.
Before the speaker walk test is complete, carry out any of the following actions:
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6940
5. To exit the self-diagnostic mode, turn the ACM off.
Satellite Digital Audio Receiver System (SDARS) Module Electronic Serial Number (ESN) Retrieval
- Vehicles Without Navigation
1. Operate the audio system in satellite radio mode.
2. Press and hold the AUX button and preset button 1, simultaneously.
- The Satellite Digital Audio Receiver System (SDARS) module Electronic Serial Number (ESN)
displays on the screen.
3. Record the SDARS module ESN.
4. Turn the audio system off.
Audio Systems With Navigation
1. Turn the Audio Control Module (ACM) on.
2. Operate the audio system in radio tuner (AM/FM) mode.
3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins.
- The display indicates each speaker as it is tested.
4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after this
step, or by allowing the speaker walk test to
complete on its own.
Before the speaker walk test is complete, press the "End Test" selection.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6941
5. The following tests are available through the "BEZEL DIAGNOSTICS" menu:
6. To exit the self-diagnostic mode, press the "Exit Diagnostics" selection from the "BEZEL
DIAGNOSTICS" menu.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6942
Communications Control Module: Removal and Replacement
Audio Control Module (ACM)
Audio Control Module (ACM)
Removal and Installation
NOTE: It is not necessary to remove the Audio Control Module (ACM) to retrieve the part number.
For additional information, refer to Audio Control Module (ACM) Self-Diagnostic Mode See:
Procedures/Audio Control Module (ACM) Self-Diagnostic Mode.
1. NOTE: Module configuration is required when a new ACM is being installed.
Upload the ACM configuration information to the scan tool.
2. Remove the instrument panel center finish panel.
3. Remove the 4 screws and the ACM.
- Disconnect the ACM electrical connectors.
4. To install, reverse the removal procedure.
- Download the configuration information to the ACM.
Accessory Protocol Interface Module (APIM)
Accessory Protocol Interface Module (APIM)
Floor Console Components
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6943
Accessory Protocol Interface Module (APIM)
Removal and Installation
1. NOTE: It is necessary to record the current Accessory Protocol Interface Module (APIM)
software and hardware level when a new APIM is being
installed to make sure that the new component is the same version as the component being
replaced.
Retrieve and record the current APIM software and hardware level. For additional information, refer
to Accessory Protocol Interface Module (APIM) Software Level Check See: Procedures/Accessory
Protocol Interface Module (APIM) Software Level Check.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6944
2. Remove the 4 screws and the front floor console stowage door.
3. Remove the 2 screws and the front floor console rear trim panel.
- Pull straight back to disengage the clips.
4. Remove the 2 screws and the front floor console finish panel.
- Pull straight up to disengage the clips.
5. Remove the front floor console stowage bin.
- Remove the 4 screws.
- Disconnect the audio input jack electrical connector.
- Disconnect the Universal Serial Bus (USB) port electrical connector.
- Disconnect the APIM electrical connector.
- Disconnect the USB cable electrical connector (at the APIM).
6. Remove the 4 screws and the APIM.
7. To install, reverse the removal procedure.
- If a new APIM is being installed, program the APIM to the correct software level.
Universal Serial Bus (USB) Cable and Port
Universal Serial Bus (USB) Cable and Port
Floor Console Components
Universal Serial Bus (USB) Cable And Port-To-Bezel
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6945
USB Cable And Port-To-Accessory Protocol Interface Module (APIM)
Removal and Installation
1. Remove the 4 screws and the front floor console stowage door.
2. Remove the 2 screws and the front floor console rear trim panel.
- Pull straight back to disengage the clips.
3. Remove the 2 screws and the front floor console finish panel.
- Pull straight up to disengage the clips.
4. Using a suitable tool (such as a trim removal tool) pry the audio input jack bezel from the storage
bin.
- Disconnect the audio input jack electrical connector.
5. Disconnect the Universal Serial Bus (USB) port connector from the audio input jack bezel.
6. Remove the 4 screws and the front floor console stowage bin.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6946
7. Remove the USB cable and port.
- Disconnect the electrical connector.
8. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6955
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 (V6-4.0L (2009))
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 6956
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6961
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 (V6-4.0L (2009))
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 6962
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 (V6-4.0L (2009))
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 6963
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 (V6-4.0L (2009))
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09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6964
^ 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 (V6-4.0L (2009))
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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 6965
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 (V6-4.0L (2009))
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 6966
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 (V6-4.0L (2009))
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 6967
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 (V6-4.0L (2009))
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 6968
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 (V6-4.0L (2009))
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 6969
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 (V6-4.0L (2009))
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 6970
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 (V6-4.0L (2009))
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 6971
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 (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 6977
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 (V6-4.0L (2009))
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 6978
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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
6983
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 (V6-4.0L (2009))
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
6984
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 (V6-4.0L (2009))
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
6985
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 (V6-4.0L (2009))
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
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6986
^ 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 (V6-4.0L (2009))
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
6987
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 (V6-4.0L (2009))
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
6988
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 (V6-4.0L (2009))
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
6989
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 (V6-4.0L (2009))
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
6990
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 (V6-4.0L (2009))
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
6991
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 (V6-4.0L (2009))
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
6992
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 (V6-4.0L (2009))
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
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6993
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 6998
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 (V6-4.0L (2009))
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 6999
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 7005
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 (V6-4.0L (2009))
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 7006
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > Page 7020
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > Page 7021
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 7030
^ 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 (V6-4.0L (2009))
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 7031
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 7037
^ 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 (V6-4.0L (2009))
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 7038
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 7047
^ 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 (V6-4.0L (2009))
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 7048
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 7054
^ 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 (V6-4.0L (2009))
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 7055
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 (V6-4.0L (2009))
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
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Equipment > Parking Assist Control Module > Component Information > Locations > Page 7059
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Equipment > Parking Assist Control Module > Component Information > Locations > Page 7060
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Equipment > Parking Assist Control Module > Component Information > Locations > Page 7061
Parking Assist Control Module: Diagrams
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Equipment > Parking Assist Control Module > Component Information > Locations > Page 7062
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Equipment > Parking Assist Control Module > Component Information > Locations > Page 7063
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Equipment > Parking Assist Control Module > Component Information > Locations > Page 7064
Parking Assist Control Module: Service and Repair
Parking Aid Module (PAM) - Explorer
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 bolts.
6. Remove the PAM assembly.
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left
Parking Assist Distance Sensor: Locations Parking Aid Sensor, Outer Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left >
Page 7070
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Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left >
Page 7071
Parking Assist Distance Sensor: Locations Parking Aid Sensor, Outer Right
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Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left >
Page 7072
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Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left >
Page 7073
Parking Assist Distance Sensor: Locations Parking Aid Sensor, Inner Left
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Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left >
Page 7074
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Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left >
Page 7075
Parking Assist Distance Sensor: Locations Parking Aid Sensor, Inner Right
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Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left >
Page 7076
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Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left >
Page 7079
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Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left >
Page 7080
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Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left >
Page 7081
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Pedal Positioning Switch > Component Information > Locations
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Equipment > Pedal Positioning Switch > Component Information > Locations > Page 7085
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Remote Switch, Audio - Stereo > Component Information > Locations
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Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 7089
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module >
Component Information > Locations > Page 7094
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in 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.
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.
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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
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Component Information > Diagrams > Diagram Information and Instructions > Page 7100
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
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Component Information > Diagrams > Diagram Information and Instructions > Page 7101
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
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Component Information > Diagrams > Diagram Information and Instructions > Page 7102
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
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
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Component Information > Diagrams > Diagram Information and Instructions > Page 7103
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery 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 loose
clothing.
Symbols
Symbols (Part 1)
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Component Information > Diagrams > Diagram Information and Instructions > Page 7104
Symbols (Part 2)
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Component Information > Diagrams > Diagram Information and Instructions > Page 7105
Symbols (Part 3)
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Component Information > Diagrams > Diagram Information and Instructions > Page 7106
Symbols (Part 4)
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Component Information > Diagrams > Diagram Information and Instructions > Page 7107
Symbols (Part 5)
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Component Information > Diagrams > Diagram Information and Instructions > Page 7108
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.
Defective insulation stripping
1 = Proper crimp
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Component Information > Diagrams > Diagram Information and Instructions > Page 7109
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
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Component Information > Diagrams > Diagram Information and Instructions > Page 7110
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
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Component Information > Diagrams > Diagram Information and Instructions > Page 7111
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
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Component Information > Diagrams > Diagram Information and Instructions > Page 7112
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7113
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.
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.
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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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Component Information > Diagrams > Diagram Information and Instructions > Page 7115
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Component Information > Diagrams > Diagram Information and Instructions > Page 7116
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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Component Information > Diagrams > Diagram Information and Instructions > Page 7117
Trailer Connector: Connector Views
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Component Information > Diagrams > Diagram Information and Instructions > Page 7118
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Component Information > Diagrams > Diagram Information and Instructions > Page 7119
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
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95-2
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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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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Information > Service and Repair > Page 7125
EXPLORER/MOUNTAINEER TEMPLATE # 1, LEFT HAND INNER SIDE VIEW, RIGHT HAND
SYMMETRICALLY OPPOSITE
5. Drill 18 mm (0.688 in) diameter holes for the inboard and outboard attachments to each frame
rail.
- For the inboard side use Explorer/Mountaineer template No. 2.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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EXPLORER/MOUNTAINEER TEMPLATE # 2, LEFT HAND INNER SIDE VIEW, RIGHT HAND
INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER
- For the outboard side use Explorer/Mountaineer template No. 3.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Service and Repair > Page 7127
EXPLORER/MOUNTAINEER TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND
INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER
Explorer Sport Trac
6. Cut the rear rails vertically at least 10-18 mm (0.39-0.70 in) behind the rear body/box mount leg.
- Use Sport Trac template No. 1.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Service and Repair > Page 7128
SPORT TRAC TEMPLATE # 1, LEFT HAND INNER SIDE VIEW, RIGHT HAND
SYMMETRICALLY OPPOSITE
7. Drill 18 mm (0.688 in) diameter holes for the inboard and outboard attachments to each frame
rail.
- Use Sport Trac Template No. 2.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Service and Repair > Page 7129
SPORT TRAC TEMPLATE # 2, LEFT HAND INNER SIDE VIEW, RIGHT HAND INNER
SYMMETRICALLY OPPOSITE TO LEFT HAND INNER
- Use Sport Trac template No. 3.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Service and Repair > Page 7130
SPORT TRAC TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND INNER
SYMMETRICALLY OPPOSITE TO LEFT HAND INNER
All vehicles
8. Deburr 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 (V6-4.0L (2009))
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Information > Service and Repair > Page 7131
Insert the new trailer hitch crossmember assembly into the frame.
12. Hand-start all 8 bolts into the weld nuts in the hitch brackets. 13. Tighten the inboard bolts.
- Tighten to 235 Nm (174 lb-ft).
14. Tighten the outboard bolts.
- Tighten to 235 Nm (174 lb-ft).
15. Install the trailer wiring harness. 16. Install the rear bumper cover. 17. Install the spare tire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions
Trailer Lamps: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7137
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7138
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7139
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
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7140
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery 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 loose
clothing.
Symbols
Symbols (Part 1)
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Information > Diagrams > Diagram Information and Instructions > Page 7141
Symbols (Part 2)
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Information > Diagrams > Diagram Information and Instructions > Page 7142
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 7143
Symbols (Part 4)
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Information > Diagrams > Diagram Information and Instructions > Page 7144
Symbols (Part 5)
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 7145
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.
Defective insulation stripping
1 = Proper crimp
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7146
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7147
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7148
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7149
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7150
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.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7151
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 (V6-4.0L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7152
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Information > Diagrams > Diagram Information and Instructions > Page 7153
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7154
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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95-2
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Information > Diagrams > Diagram Information and Instructions > Page 7156
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 (V6-4.0L (2009))
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
Special Tools Used With Diagnostics
Trailer Lamps
Principles Of Operation
Trailer Lamps
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 stop/turn lamps.
The trailer parking and reversing lamps share the vehicle lighting outputs.
The vehicle is supplied with wiring to support an aftermarket .
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 Field-Effect Transistor (FET) protective circuit strategy for many of its outputs
(for example, a 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 event is detected. A continuous DTC is stored at the fault event and a
cumulative counter is started.
When the demand for the output is no longer present, the module resets the FET circuit protection
to allow the circuit to function. The next time the driver requests a circuit to activate that has been
shut down by a previous short (FET protection) and the circuit remains shorted, the FET protection
shuts off the circuit again and the cumulative counter advances.
When the excessive circuit load occurs often enough, the module shuts down the output until a
repair procedure is carried out. Each FET protected circuit has 3 predefined levels of short circuit
tolerance based on the harmful effect of each circuit fault on the FET and the ability of the FET to
withstand it. A module lifetime level of fault events is established based upon the durability of the
FET. If the total tolerance level is determined to be 600 fault events, the 3 predefined levels would
be 200, 400 and 600 fault events.
When each tolerance level is reached, 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 operation until a successful self-test proves that
the fault has been repaired. After the self-test has successfully completed (no on-demand DTCs
present), the continuous DTC automatically clears and the circuit function returns.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7159
When the first or second level is reached, the continuous DTC (associated with the short circuit)
sets along with DTC B106E. These DTCs can be cleared using the module on-demand self-test,
then the Clear DTC operation on the scan tool (if the on-demand test shows the fault corrected).
The module never resets the fault event counter to zero and continues to advance the fault event
counter as short circuit fault events occur.
If the number of short circuit fault events reach the third level, then DTCs B106F and B1342 set
along with the associated continuous DTC. This DTC 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
Trailer Lamps
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
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.
NOTE: Make sure the multifunction switch is in the LOW BEAM position.
5. 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).
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, No Power To The Scan Tool, to diagnose no power to 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 to diagnose no response from the PCM.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7160
8. Carry out the network test.
- If the scan tool responds with no communication with the SJB, refer to Information Bus.
- 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 Diagnostic Trouble Code (DTC) Chart
See: Lighting and Horns/Testing and Inspection.
For all other DTCs, refer to the Diagnostic Trouble Code (DTC) Chart in Body Control Systems.
See: Body and Frame/Body Control Systems/Testing and Inspection/Diagnostic Trouble Code
Descriptions/Diagnostic Trouble Code (DTC) Chart
11. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7161
Trailer Lamps: Symptom Related Diagnostic Procedures
Trailer Lamps
Symptom Chart
Symptom Chart (Part 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7162
Symptom Chart (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7163
Trailer Lamps: Pinpoint Tests
Pinpoint Test W: All The Trailer Lamps Are Inoperative
Trailer Lamps
Pinpoint Tests
Pinpoint Test W: All the Trailer Lamps Are Inoperative
Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
Normal Operation
Ground for all the 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
PINPOINT TEST W: ALL THE TRAILER LAMPS ARE INOPERATIVE
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of
corrosion or damage. Repair or install a new trailer tow connector as required.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- W1 CHECK CIRCUIT RAT08 (WH) FOR AN OPEN TO THE
TRAILER TOW CONNECTOR
- Disconnect the trailer from the vehicle.
- Disconnect: Negative Battery Cable.
- For the 4-pin connector, measure the resistance between the trailer tow C439-4, circuit RAT08
(WH), harness side and ground.
- For the 7-pin connector, measure the resistance between the trailer tow connector pin 2, circuit
RAT08 (WH), component side and ground.
- Is the resistance less than 5 ohms?
Yes
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
No
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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For the 4-pin connector, REPAIR the circuit. TEST the system for normal operation.
For the 7-pin connector, GO to W2.
------------------------------------------------- W2 CHECK CIRCUIT RAT08 (WH) FOR AN OPEN
- Disconnect: Trailer Tow C473.
- Measure the resistance between the trailer tow C473-2, circuit RAT08 (WH), harness side and
ground.
- Is the resistance less than 5 ohms?
Yes
INSTALL a new trailer tow connector. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------Pinpoint Test X: The Trailer Lamps Are Inoperative - Parking Lamps
Trailer Lamps
Pinpoint Tests
Pinpoint Test X: The Trailer Lamps Are Inoperative - Parking Lamps
Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
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
PINPOINT TEST X: THE TRAILER LAMPS ARE INOPERATIVE - PARKING LAMPS
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of
corrosion or damage. Repair or install a new trailer tow connector as required.
------------------------------------------------- X1 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR
- Ignition OFF.
- Disconnect the trailer from the vehicle.
- Place the headlamp switch in the PARKING LAMPS ON position.
- For the 4-pin connector, measure the voltage between the trailer tow C439-3, circuit CAT17 (BN),
harness side and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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- For the 7-pin connector, measure the voltage between the trailer tow connector pin 6, circuit
CAT17 (BN), component side and ground.
- Is the voltage greater than 10 volts?
Yes
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
No
VERIFY the SJB fuse 25 (15A) is OK.
If OK for the 4-pin connector, GO to X3.
If OK for the 7-pin connector, GO to X2.
If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short.
------------------------------------------------- X2 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR (7-PIN)
- Disconnect: Trailer Tow C473.
- Measure the voltage between the trailer tow C473-6, circuit CAT17 (BN), harness side and
ground.
- Is the voltage greater than 10 volts?
Yes
INSTALL a new trailer tow connector. TEST the system for normal operation.
No
GO to X3.
------------------------------------------------- X3 CHECK CIRCUIT CAT17 (BN) FOR AN OPEN
- Place the headlamp switch in the OFF position.
- Disconnect: SJB C2280a.
- Measure the resistance between the SJB C2280a-13, circuit CAT17 (BN), harness side and the
trailer tow C439-3 (4-pin connector) or C473-6 (7-pin connector), circuit CAT17 (BN), harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7166
- Is the resistance less than 5 ohms?
Yes
GO to X4.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- X4 CHECK FOR CORRECT SJB OPERATION
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new SJB. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector.
------------------------------------------------Pinpoint Test Y: The Trailer Lamps Are Inoperative - Reversing Lamps
Trailer Lamps
Pinpoint Tests
Pinpoint Test Y: The Trailer Lamps Are Inoperative - Reversing Lamps
Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
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
PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE - REVERSING LAMPS
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7167
connector.
NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of
corrosion or damage. Repair or install a new trailer tow connector as required.
------------------------------------------------- Y1 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR
- Ignition OFF.
- Disconnect the trailer from the vehicle.
- Apply the parking brake.
- Ignition ON.
- Select REVERSE.
- Measure the voltage between the trailer tow connector pin 7, circuit CAT16 (GY/BN), component
side and ground.
- Is the voltage greater than 10 volts?
Yes
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
No
VERIFY the SJB fuse 16 (10A) is OK. If OK, GO to Y2. If not OK, REFER to the Wiring Diagrams
to identify the possible causes of the circuit short.
------------------------------------------------- Y2 CHECK FOR VOLTAGE ON CIRCUIT CAT16 (GY/BN)
- Disconnect: Trailer Tow C473.
- Measure the voltage between the trailer tow C473-7, circuit CAT16 (GY/BN), harness side and
ground.
- Is the voltage greater than 10 volts?
Yes
INSTALL a new trailer tow connector. TEST the system for normal operation.
No
GO to Y3.
------------------------------------------------- Y3 CHECK CIRCUIT CAT16 (GY/BN) FOR AN OPEN
- Select PARK.
- Ignition OFF.
- Disconnect: SJB C2280a.
- Measure the resistance between the SJB C2280a-21, circuit CAT16 (GY/BN), harness side and
the trailer tow C473-7, circuit CAT16 (GY/BN), harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7168
- Is the resistance less than 5 ohms?
Yes
GO to Y4.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- Y4 CHECK FOR CORRECT SJB OPERATION
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new SJB. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector.
------------------------------------------------Pinpoint Test Z: The Individual Trailer Lamp Is Inoperative - LH Stop/Turn Lamp
Trailer Lamps
Pinpoint Tests
Pinpoint Test Z: The Individual Trailer Lamp Is Inoperative - LH Stop/Turn Lamp
Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
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) - 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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7169
PINPOINT TEST Z: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - LH STOP/TURN LAMP
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of
corrosion or damage. Repair or install a new trailer tow connector as required.
------------------------------------------------- Z1 CHECK THE RECORDED DTCs FROM THE SJB
SELF-TEST
- Check the recorded results from the SJB self-test.
- Was DTC B2070 present?
Yes
GO to Z2.
No
GO to Z6.
------------------------------------------------- Z2 CLEAR THE DTCs AND REPEAT THE ON-DEMAND
SELF-TEST WITH THE TRAILER DISCONNECTED
- Disconnect the trailer from the vehicle.
- Enter the following diagnostic mode on the scan tool: SJB Self-Test.
- Clear the continuous DTCs. Repeat the on-demand self-test.
- Is DTC B2070 still present?
Yes
For the 4-pin connector, GO to Z5.
For the 7-pin connector, GO to Z4.
No
GO to Z3.
------------------------------------------------- Z3 CHECK THE NUMBER OF BULBS ON THE TRAILER
- Inspect the trailer for more than 2 LH stop/turn lamp bulbs.
- Are more than 2 LH stop/turn lamp bulbs present?
Yes
INFORM the customer that the vehicle can only support 2 stop/turn lamp bulbs per side. Any
additional stop/turn lamp bulbs need to be removed from the trailer or an adapter kit installed for
the trailer tow lamps to operate correctly.
No
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
------------------------------------------------- Z4 CHECK THE TRAILER TOW CONNECTOR
- Disconnect: Trailer Tow C473.
- Enter the following diagnostic mode on the scan tool: SJB Self-Test.
- Clear the continuous DTCs. Repeat the on-demand self-test.
- Is DTC B2070 still present?
Yes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7170
GO to Z5.
No
INSTALL a new trailer tow connector. TEST the system for normal operation.
------------------------------------------------- Z5 CHECK CIRCUIT CAT06 (YE) FOR A SHORT TO
GROUND
- Ignition OFF.
- Disconnect: SJB C2280a.
- Measure the resistance between the SJB C2280a-14, circuit CAT06 (YE), harness side and
ground.
- Is the resistance greater than 10,000 ohms?
Yes
GO to Z9.
No
REPAIR the circuit. RUN the on-demand self-test (required to clear certain DTCs). CORRECT any
unresolved DTCs. CLEAR all DTCs. TEST the system for normal operation.
------------------------------------------------- Z6 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR
- Disconnect the trailer from the vehicle.
- Ignition OFF.
- For the 4-pin connector, while applying the brake pedal, measure the voltage between the trailer
tow C439-2, circuit CAT06 (YE), harness side and ground.
- For the 7-pin connector, while applying the brake pedal, measure the voltage between the trailer
tow connector pin 1, circuit CAT06 (YE), component side and ground.
- Is the voltage greater than 10 volts?
Yes
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
TEST the system for normal operation.
No
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7171
For the 4-pin connector, GO to Z8.
For the 7-pin connector, GO to Z7.
------------------------------------------------- Z7 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR (7-PIN)
- Disconnect: Trailer Tow C473.
- While applying the brake pedal, measure the voltage between the trailer tow C473-1, circuit
CAT06 (YE), harness side and ground.
- Is the voltage greater than 10 volts?
Yes
INSTALL a new trailer tow connector. TEST the system for normal operation.
No
GO to Z8.
------------------------------------------------- Z8 CHECK CIRCUIT CAT06 (YE) FOR AN OPEN
- Disconnect: SJB C2280a.
- Measure the resistance between the SJB C2280a-14, circuit CAT06 (YE), harness side and the
trailer tow C439-2 (4-pin) or C473-1 (7-pin), circuit CAT06 (YE), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to Z9.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- Z9 CHECK FOR CORRECT SJB OPERATION
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7172
INSTALL a new SJB. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the self-test.
------------------------------------------------Pinpoint Test AA: The Individual Trailer Lamp Is Inoperative - RH Stop/Turn Lamp
Trailer Lamps
Pinpoint Tests
Pinpoint Test AA: The Individual Trailer Lamp Is Inoperative - RH Stop/Turn Lamp
Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
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) - 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
PINPOINT TEST AA: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - RH STOP/TURN
LAMP
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of
corrosion or damage. Repair or install a new trailer tow connector as required.
------------------------------------------------- AA1 CHECK THE RECORDED DTCs FROM THE SJB
SELF-TEST
- Check the recorded results from the SJB self-test.
- Was DTC B2070 present?
Yes
GO to AA2.
No
GO to AA6.
------------------------------------------------- AA2 CLEAR THE DTCs AND REPEAT THE ON-DEMAND
SELF-TEST WITH THE TRAILER DISCONNECTED
- Disconnect the trailer from the vehicle.
- Enter the following diagnostic mode on the scan tool: SJB Self-Test.
- Clear the continuous DTCs. Repeat the on-demand self-test.
- Is DTC B2070 still present?
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7173
Yes
For the 4-pin connector, GO to AA5.
For the 7-pin connector, GO to AA4.
No
GO to AA3.
------------------------------------------------- AA3 CHECK THE NUMBER OF BULBS ON THE TRAILER
- Inspect the trailer for more than 2 RH stop/turn lamp bulbs.
- Are more than 2 RH stop/turn lamp bulbs present?
Yes
INFORM the customer that the vehicle can only support 2 stop/turn lamp bulbs per side. Any
additional stop/turn lamp bulbs need to be removed from the trailer or an adapter kit installed for
the trailer tow lamps to operate correctly.
No
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
------------------------------------------------- AA4 CHECK THE TRAILER TOW CONNECTOR
- Disconnect: Trailer Tow 473.
- Enter the following diagnostic mode on the scan tool: SJB Self-Test.
- Clear the continuous DTCs. Repeat the on-demand self-test.
- Is DTC B2070 still present?
Yes
GO to AA5.
No
INSTALL a new trailer tow connector. TEST the system for normal operation.
------------------------------------------------- AA5 CHECK CIRCUIT CAT09 (GN) FOR A SHORT TO
GROUND
- Ignition OFF.
- Disconnect: SJB C2280a.
- Measure the resistance between the SJB C2280a-26, circuit CAT09 (GN), harness side and
ground.
- Is the resistance greater than 10,000 ohms?
Yes
GO to AA9.
No
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7174
REPAIR the circuit. RUN the on-demand self-test (required to clear certain DTCs). CORRECT any
unresolved DTCs. CLEAR all DTCs. TEST the system for normal operation.
------------------------------------------------- AA6 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR
- Ignition OFF.
- Disconnect the trailer from the vehicle.
- For the 4-pin connector, while applying the brake pedal, measure the voltage between the trailer
tow C439-1, circuit CAT09 (GN), harness side and ground.
- For the 7-pin connector, while applying the brake pedal, measure the voltage between the trailer
tow connector pin 4, circuit CAT09 (GN), component side and ground.
- Is the voltage greater than 10 volts?
Yes
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
TEST the system for normal operation.
No
For the 4-pin connector, GO to AA8.
For the 7-pin connector, GO to AA7.
------------------------------------------------- AA7 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR (7-PIN)
- Disconnect: Trailer Tow C473.
- While applying the brake pedal, measure the voltage between the trailer tow C473-4, circuit
CAT09 (GN), harness side and ground.
- Is the voltage greater than 10 volts?
Yes
INSTALL a new trailer tow connector. TEST the system for normal operation.
No
GO to AA8.
------------------------------------------------- AA8 CHECK CIRCUIT CAT09 (GN) FOR AN OPEN
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7175
- Disconnect: SJB C2280a.
- Measure the resistance between the SJB C2280a-26, circuit CAT09 (GN), harness side and the
trailer tow C439-1 (4-pin) or C473-4 (7-pin), circuit CAT09 (GN), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to AA9.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- AA9 CHECK FOR CORRECT SJB OPERATION
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new SJB. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the self-test.
------------------------------------------------Pinpoint Test AB: The Trailer Lamps Are On Continuously
Trailer Lamps
Pinpoint Tests
Pinpoint Test AB: The Trailer Lamps Are On Continuously
Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
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.
The trailer tow parking lamps share the same voltage supply with the vehicle parking lamps.
This pinpoint test is intended to diagnose the following:
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7176
- Wiring, terminals or connectors
- Trailer
- SJB
PINPOINT TEST AB: THE TRAILER LAMPS ARE ON CONTINUOUSLY
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of
corrosion or damage. Repair or install a new trailer tow connector as required.
------------------------------------------------- AB1 CHECK FOR VOLTAGE AT THE TRAILER TOW
CONNECTOR
- Ignition OFF.
- Disconnect the trailer from the vehicle.
- Ignition ON.
- Measure the voltage between the trailer tow connector, harness side and ground as follows:
- Is any voltage present?
Yes
GO to AB2.
No
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
------------------------------------------------- AB2 CHECK THE SJB
- Ignition OFF.
- Disconnect: SJB C2280a.
- Ignition ON.
- Measure the voltage between the trailer tow connector, harness side and ground as follows:
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7177
- Is any voltage present?
Yes
REPAIR the circuit in question. TEST the system for normal operation.
No
GO to AB3.
------------------------------------------------- AB3 CHECK FOR CORRECT SJB OPERATION
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new SJB. CLEAR any DTCs. REPEAT the self-test.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector.
------------------------------------------------Pinpoint Test AC: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly
Trailer Lamps
Pinpoint Tests
Pinpoint Test AC: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly
Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7178
PINPOINT TEST AC: THE TRAILER BATTERY CHARGING IS INOPERATIVE/DOES NOT
OPERATE CORRECTLY
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of
corrosion or damage. Repair or install a new trailer tow connector as required.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- AC1 CHECK FOR VOLTAGE AT THE TRAILER TOW
CONNECTION (BATTERY CHARGE INOPERATIVE)
- Ignition OFF.
- Disconnect the trailer from the vehicle.
- Ignition ON.
- Measure the voltage between the trailer tow connector pin 5, circuit CAT14 (OG), component side
and ground.
Is the voltage greater than 10 volts?
Yes
GO to AC8.
No
VERIFY the BJB fuse 13 (30A) is OK. If OK, GO to AC2. If not OK, REFER to the Wiring Diagrams
to identify the possible causes of the circuit short.
------------------------------------------------- AC2 CHECK THE TRAILER BATTERY CHARGE RELAY
(INOPERATIVE)
- Ignition OFF.
- Disconnect: Trailer Battery Charge Relay.
- Substitute the trailer battery charge relay with a known good relay.
- Ignition ON.
- Measure the voltage between the trailer tow connector pin 5, circuit CAT14 (OG), component side
and ground.
- Is the voltage greater than 10 volts?
Yes
REMOVE the known good relay. INSTALL a new trailer battery charge relay. TEST the system for
normal operation.
No
REMOVE the known good relay. INSTALL the original relay. GO to AC3.
-------------------------------------------------
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7179
AC3 CHECK THE TRAILER TOW CONNECTOR
- Ignition OFF.
- Disconnect: Trailer Tow C473.
- Ignition ON.
- Measure the voltage between the trailer tow C473-5, circuit CAT14 (OG) and ground.
Is the voltage greater than 10 volts?
Yes
INSTALL a new trailer tow connector. TEST the system for normal operation.
No
GO to AC4.
------------------------------------------------- AC4 CHECK FOR VOLTAGE TO THE TRAILER BATTERY
CHARGE RELAY COIL
- Ignition OFF.
- Disconnect: Trailer Battery Charge Relay.
- Ignition ON.
- Measure the voltage between the trailer battery charge relay pin 86, circuit CBP12 (GN/WH), BJB
face side and ground.
- Is the voltage greater than 10 volts?
Yes
GO to AC6.
No
VERIFY the SJB fuse 12 (5A) is OK. If OK, GO to AC5. If not OK, REFER to the Wiring Diagrams
to identify the possible causes of the circuit short.
------------------------------------------------- AC5 CHECK CIRCUIT CBP12 (GN/WH) FOR AN OPEN
- Ignition OFF.
- Disconnect: SJB C2280e.
- Measure the resistance between trailer battery charge relay pin 86, circuit CBP12 (GN/WH), BJB
face side and the SJB C2280e-6, circuit CBP12 (GN/WH), harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7180
- Is the resistance less than 5 ohms?
Yes
GO to AC12.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- AC6 CHECK CIRCUIT GD120 (BK/GN) FOR AN OPEN
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the trailer battery charge relay pin 85, circuit GD120 (BK/GN),
BJB face side and ground.
- Is the resistance less than 5 ohms?
Yes
GO to AC7.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- AC7 CHECK FOR VOLTAGE TO THE TRAILER BATTERY
CHARGE RELAY
- Measure the voltage between the trailer battery charge relay pin 30, circuit SSB13 (GY/RD), BJB
face side and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7181
- Is the voltage greater than 10 volts?
Yes
REPAIR circuit CAT14 (OG) for an open. TEST the system for normal operation.
No
REPAIR circuit SSB13 (GY/RD) for an open. TEST the system for normal operation.
------------------------------------------------- AC8 CHECK FOR VOLTAGE AT THE TRAILER TOW
CONNECTOR (BATTERY CHARGE ALWAYS ON)
- Ignition OFF.
- Measure the voltage between the trailer tow connector pin 5, circuit CAT14 (OG), component side
and ground.
- Is any voltage present?
Yes
GO to AC9.
No
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
------------------------------------------------- AC9 CHECK CIRCUIT CAT14 (OG) FOR A SHORT TO
VOLTAGE
- Disconnect: Trailer Battery Charge Relay.
- Measure the voltage between the trailer tow connector pin 5, circuit CAT14 (OG), component side
and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7182
- Is any voltage present?
Yes
REPAIR the circuit. TEST the system for normal operation.
No
GO to AC10.
------------------------------------------------- AC10 CHECK THE TRAILER BATTERY CHARGE RELAY
(ALWAYS ON)
- Measure the voltage between the trailer battery charge relay pin 86, circuit CBP12 (GN/WH), BJB
face side and ground.
- Is any voltage present?
Yes
GO to AC11.
No
INSTALL a new trailer battery charge relay. TEST the system for normal operation.
------------------------------------------------- AC11 CHECK CIRCUIT CBP12 (GN/WH) FOR A SHORT TO
VOLTAGE
- Disconnect: SJB C2280e.
- Measure the voltage between the trailer battery charge relay pin 86, circuit CBP12 (GN/WH),
harness side and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7183
Is any voltage present?
Yes
REPAIR the circuit. TEST the system for normal operation.
No
GO to AC12.
------------------------------------------------- AC12 CHECK FOR CORRECT SJB OPERATION
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new SJB. CLEAR any DTCs. REPEAT the self-test.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector.
------------------------------------------------Pinpoint Test AD: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly
Trailer Lamps
Pinpoint Tests
Pinpoint Test AD: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly
Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
Normal Operation
The 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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7184
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- TBC module
- Trailer tow connector
- Trailer
PINPOINT TEST AD: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE/DO NOT
OPERATE CORRECTLY
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of
corrosion or damage. Repair or install a new trailer tow connector as required.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- AD1 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR (INOPERATIVE CONDITION)
- Ignition OFF.
- Disconnect the trailer from the vehicle.
- While applying the brake pedal, measure the voltage between the trailer tow connector pin 3,
circuit CAT19 (BU), component side and ground.
- Is the voltage greater than 10 volts?
Yes
GO to AD8.
No
GO to AD2.
------------------------------------------------- AD2 CHECK THE TRAILER TOW CONNECTOR
- Disconnect: Trailer Tow C473.
- While applying the brake pedal, measure the voltage between the trailer tow C473-3, circuit
CAT19 (BU), harness side and ground.
- Is the voltage greater than 10 volts?
Yes
INSTALL a new trailer tow connector. TEST the system for normal operation.
No
GO to AD3.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7185
------------------------------------------------- AD3 CHECK CIRCUIT SBB17 (RD) FOR AN OPEN
- Disconnect: C238.
- Measure the voltage between the TBC module C238-1, circuit SBB17 (RD), harness side and
ground.
- Is the voltage greater than 10 volts?
Yes
GO to AD4.
No
VERIFY the BJB fuse 17 (30A) is OK. If OK, REPAIR the circuit. TEST the system for normal
operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit
short.
------------------------------------------------- AD4 CHECK CIRCUIT CCB08 (VT/WH) FOR AN OPEN
- While applying the brake pedal, measure the voltage between the TBC module C238-2, circuit
CCB08 (VT/WH), harness side and ground.
- Is the voltage greater than 10 volts?
Yes
GO to AD5.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- AD5 CHECK CIRCUIT GD138 (BK/WH) FOR AN OPEN
- Disconnect: Negative Battery Cable.
- Measure the resistance between the TBC module C238-6, circuit GD138 (BK/WH), harness side
and ground.
- Is the resistance less than 5 ohms?
Yes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7186
GO to AD6.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- AD6 CHECK CIRCUIT CAT19 (BU) FOR A SHORT TO
GROUND
- Measure the resistance between the TBC module C238-3, circuit CAT19 (BU), harness side and
ground.
- Is the resistance greater than 10,000 ohms?
Yes
GO to AD7.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- AD7 CHECK CIRCUIT CAT19 (BU) FOR AN OPEN
- Measure the resistance between the TBC module C238-3, circuit CAT19 (BU), harness side and
the trailer tow C473-3, circuit CAT19 (BU), harness side.
- Is the resistance less than 5 ohms?
Yes
INSTALL a new TBC module. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- AD8 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR (DOES NOT OPERATE CORRECTLY)
- With the brake pedal released, measure the voltage between the trailer tow connector pin 3,
circuit CAT19 (BU), component side and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7187
- Is any voltage present?
Yes
GO to AD9.
No
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
------------------------------------------------- AD9 CHECK CIRCUIT CAT19 (BU) FOR A SHORT TO
VOLTAGE
- Disconnect: TBC Module C238.
- Measure the voltage between the trailer tow connector pin 3, circuit CAT19 (BU), component side
and ground.
- Is any voltage present?
Yes
REPAIR the circuit. TEST the system for normal operation.
No
INSTALL a new TBC module. TEST the system for normal operation.
-------------------------------------------------
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Locations > Page 7191
Trailer Lighting Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Locations > Page 7192
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay >
Component Information > Locations > Page 7196
Trailer Towing Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay >
Component Information > Locations > Page 7197
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7202
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7203
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7204
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7205
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
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7206
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery 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 loose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7207
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7208
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7209
Symbols (Part 4)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7210
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7211
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.
Defective insulation stripping
1 = Proper crimp
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7212
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7213
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7214
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7215
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7216
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.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7217
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 (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7218
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7219
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7220
Trailer Connector: Connector Views
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7221
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7222
Trailer Connector: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
95-1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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> Diagram Information and Instructions > Page 7223
95-2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 7224
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Specifications
Body Control Systems: Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Specifications > Page 7229
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 modules on this vehicle are the:
- 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. Refer to Locks.
Smart Junction Box (SJB)
The SJB (located under the instrument panel on the driver side) is a combination of a multifunction
electronic 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 (V6-4.0L (2009))
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
Driver Seat Module (DSM)
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of 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, No Power To The Scan Tool, to diagnose no power to 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 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.
- 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 Diagnostic Trouble Code (DTC) Chart
See: Diagnostic Trouble Code
Descriptions/Diagnostic Trouble Code (DTC) Chart.
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
Driver Seat Module (DSM)
Principles of Operation
The Driver Seat Module (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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7232
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
inter-module and scan tool communications.
Special Tools Used With Diagnostics
Driver Seat Module (DSM)
Inspection And Verification
Smart Junction Box (SJB)
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7233
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, No Power To The Scan Tool, to diagnose no power to 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 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.
- 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 Diagnostic Trouble Code (DTC) Chart
See: Diagnostic Trouble Code
Descriptions/Diagnostic Trouble Code (DTC) Chart.
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
Smart Junction Box (SJB)
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).
Special Tools Used With Diagnostics
Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7234
Body Control Systems: Diagnostic Trouble Code Descriptions
Diagnostic Trouble Code (DTC) Chart
Diagnostic Trouble Code (DTC) Chart
NOTE: Most powertrain (P-code) DTCs are diagnosed in Computers and Control Systems
Information. If the P-code retrieved is not listed below, refer to Computers and Control Systems
Information to continue diagnostics.
NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM).
NOTE: Some of these modules utilize a 5-character DTC followed by a 2-character failure-type
code. The failure-type code provides information about specific fault conditions such as opens, or
shorts to ground. Continuous memory DTCs have an additional 2-character DTC status code suffix
to assist in determining DTC history.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7235
B106A-B1171
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7236
B11BA:1C-B1259
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7237
B1261-B1342
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7238
B1342-B1571
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7239
B1578-B1884
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7240
B1A01:01-B2027
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7241
B229A-B2296
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7242
B229B-B2607
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7243
B287A-B2986
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7244
B2987 / C1095-C1703
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7245
C1704-C2780 / P0218
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7246
P062F-P0716
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7247
P0717-P0755
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7248
P0758-P0973
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7249
P0974-P1716
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7250
PXXXX-P2764 / U0073-U0100
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7251
U0100:00-U0193
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7252
U0196-U2013
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7253
U201A:51-U2051
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7254
U261A-U3003:17
Driver Seat Module (DSM) DTC Chart
Driver Seat Module (DSM)
DTC Charts
B1317-B2143
Smart Junction Box (SJB) DTC Chart
Smart Junction Box (SJB)
DTC Charts
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7255
B106E-B2141 / U0155-U0164
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7256
Body Control Systems: Symptom Related Diagnostic Procedures
Driver Seat Module (DSM)
Driver Seat Module (DSM)
Symptom Chart
Symptom Chart
Smart Junction Box (SJB)
Smart Junction Box (SJB)
Symptom Chart
Symptom Chart
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7257
Body Control Systems: Pinpoint Tests
Pinpoint Test F: DTC B1317
Driver Seat Module (DSM)
Pinpoint Tests
Pinpoint Test F: DTC B1317
Refer to Wiring Diagram Set 117, Remote Keyless Entry and Alarm for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Normal Operation
The Driver Seat Module (DSM) monitors the voltage from the battery to determine if it goes above
or below specific thresholds and sets DTC B1317 in continuous memory if the DSM detects high
battery voltage above 15 volts on circuit SBB14 (BN/RD).
- DTC B1317 (Battery Voltage High) - a continuous memory DTC that sets when the DSM detects
battery voltage above 15 volts on circuit SBB14 (BN/RD).
This pinpoint test is intended to diagnose the following:
- Charging system concern
- DSM
PINPOINT TEST F: DTC B1317
NOTE: DTC B1317 may be stored in the module memory due to previous battery charging or
vehicle jump starting events.
------------------------------------------------- F1 CHECK FOR DTCs B1317, B1676 OR P0563 SET IN
OTHER MODULES
- Ignition ON.
- Enter the following diagnostic mode on the scan tool: (All Modules) Self-Test.
- Retrieve the continuous memory DTCs from all modules.
- Is DTC B1317, B1676 or P0563 (PCM) set in more than one module?
Yes
REFER to Charging System to diagnose an overcharging condition.
No
GO to F2.
------------------------------------------------- F2 CHECK THE BATTERY VOLTAGE
- Turn off all interior/exterior lights and accessories.
- Start and run the engine at approximately 2,000 rpm for 3 minutes while monitoring the battery
voltage.
- Does the battery voltage rise to 15 volts or higher?
Yes
REFER to Charging System to diagnose an overcharging condition.
No
GO to F3.
------------------------------------------------- F3 RECHECK FOR DTC B1317
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7258
- Turn the engine off.
- Ignition ON.
- Enter the following diagnostic mode on the scan tool: DSM Self-Test.
- Clear the continuous memory DTCs.
- Carry out the DSM self-test.
- Is DTC B1317 present?
Yes
INSTALL a new DSM. REFER to Driver Seat Module (DSM) See: Mirrors/Memory Positioning
Systems/Memory Positioning Module/Service and Repair. TEST the system for normal operation.
No
The system is operating normally at this time. The DTC may have been set previously during
battery charging or while jump starting the vehicle.
------------------------------------------------Pinpoint Test G: DTC B1318
Driver Seat Module (DSM)
Pinpoint Tests
Pinpoint Test G: DTC B1318
Refer to Wiring Diagram Set 117, Remote Keyless Entry and Alarm for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Normal Operation
The Driver Seat Module (DSM) monitors the voltage from the battery to determine if it goes above
or below specific thresholds and sets DTC B1318 in continuous memory if the DSM detects low
battery voltage below 10 volts on circuit SBB14 (BN/RD).
- DTC B1318 (Battery Voltage Low) - a continuous memory DTC that sets when the DSM detects
battery voltage below 10 volts on circuit SBB14 (BN/RD).
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- High circuit resistance
- DSM
PINPOINT TEST G: DTC B1318
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- G1 RECHECK THE DSM DTCs
- Ignition ON.
- Enter the following diagnostic mode on the scan tool: DSM Self-Test.
- Clear the DTCs. Repeat the DSM self-test.
- Is DTC B1318 still present?
Yes
GO to G2.
No
The system is operating normally at this time. The DTC may have been set previously during
battery charging or while jump starting the vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7259
------------------------------------------------- G2 CHECK FOR CHARGING SYSTEM DTCs IN THE PCM
- Enter the following diagnostic mode on the scan tool: PCM Self-Test.
- Retrieve the continuous memory DTCs from the PCM.
- Is DTC P0620, P0625, P0626 or P065B set in the PCM?
Yes
REFER to Charging System.
No
GO to G3.
------------------------------------------------- G3 CHECK THE BATTERY CONDITION AND STATE OF
CHARGE
- Ignition OFF.
- Check the battery condition and verify the battery is fully charged. Refer to Battery, Battery
Condition Test. See: Starting and Charging/Battery/Testing and Inspection/Pinpoint Tests
- Is the battery OK and fully charged?
Yes
GO to G4.
No
REFER to Charging System.
------------------------------------------------- G4 CHECK THE DSM VOLTAGE SUPPLY
- Measure and record the voltage at the battery.
- Disconnect: DSM C341A.
- Ignition ON.
- Measure the voltage between the DSM C341A-2, circuit SBB14 (BN/RD), harness side and
ground.
- Is the voltage within 0.2 volt of the recorded battery voltage?
Yes
GO to G5.
No
REPAIR the circuit for high resistance. CLEAR the DTC. REPEAT the self-test.
------------------------------------------------- G5 CHECK THE DSM GROUND CIRCUIT
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Disconnect: DSM C341C.
- Measure the resistance between the DSM C341C-13, circuit GD143 (BK/VT), harness side and
ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Inspection and Diagnostic Overview > Page 7260
- Is the resistance less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to G6.
No
REPAIR the circuit for high resistance. CONNECT the negative battery cable. TEST the system for
normal operation.
------------------------------------------------- G6 CHECK FOR CORRECT DSM OPERATION
- Disconnect the DSM connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the DSM connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
Is the concern still present?
Yes
INSTALL a new DSM. REFER to Driver Seat Module (DSM) See: Mirrors/Memory Positioning
Systems/Memory Positioning Module/Service and Repair. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector.
------------------------------------------------Pinpoint Test A: DTC B106E/B106F
Smart Junction Box (SJB)
Pinpoint Tests
Pinpoint Test A: DTC B106E/B106F
Normal Operation
The Smart Junction Box (SJB) controls the output of the Daytime Running Lamps (DRL), fog
lamps, one-touch down driver power window, accessory delay relay, windshield wiper park/run,
windshield wiper speed, and windshield washer. When a repetitive fault causing a circuit overload
is detected on any of the output circuits, the SJB disables the circuit by removing voltage, or
ground, to the affected circuit. The circuit remains disabled until the fault is corrected and an
on-demand self-test is run. After the on-demand self-test has been run, any DTCs related to the
fault will be cleared.
- DTC B106E (Module Output Pin Disabled To Protect From External Fault) - sets when the SJB
has temporarily disabled a circuit due to a repetitive fault causing a circuit overload. A
corresponding DTC for the circuit in question will also set as follows: DTC B106F (Module Disabled Due to External Fault) - sets when one or more output functions are
permanently disabled due to a repetitive circuit overload fault. DTC B106F will be set with DTC
B106E. When DTC B106F is present, the SJB must be replaced after the fault condition has been
corrected.
- DTC B1304 (Accessory Delay Relay Coil Circuit Short to Battery) - Accessory delay relay circuit
short to battery voltage
- DTC B2512 (Front Fog Lamp Relay Ckt Short to Battery) - Fog lamp relay circuit short to battery
voltage
- DTC B2973 (Daytime Running Lamp Output Shorted to Ground) - DRL output short to ground
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7261
This pinpoint test is intended to diagnose the following:
- Output circuit short to ground or voltage
- SJB
PINPOINT TEST A: DTCs B106E/B106F
NOTICE: If DTC B106F is present and the Smart Junction Box (SJB) is to be replaced, the fault
condition must be corrected first. Failure to correct the fault condition first may cause damage to
the new SJB, resulting in a repeat repair.
------------------------------------------------- A1 CHECK FOR DTC B106E
- Review the DTCs from the SJB self-test.
- Is DTC B106E present?
Yes
GO to A2.
No
GO to A3.
------------------------------------------------- A2 CHECK FOR OTHER DTCs
- Review the DTCs from the SJB self-test.
- Are any SJB DTCs present other than DTC B106E?
Yes
CORRECT any other DTCs. REFER to the Diagnostic Trouble Code (DTC) Chart See: Diagnostic
Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart. REPEAT the self-test
(on-demand DTCs).
No
CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
------------------------------------------------- A3 CHECK FOR DTC B106F
- Review the DTCs from the SJB self-test.
- Is DTC B106F present?
Yes
CORRECT any other DTCs. REFER to Diagnostic Trouble Code (DTC) Chart See: Diagnostic
Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart. INSTALL a new SJB. REFER to
Smart Junction Box (SJB) See: Power and Ground Distribution/Power Distribution Module/Service
and Repair. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern was caused by a fault in one of the
output circuits.
-------------------------------------------------
Pinpoint Test B: DTC B1317
Smart Junction Box (SJB)
Pinpoint Tests
Pinpoint Test B: DTC B1317
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7262
Refer to Wiring Diagram Set 117, Remote Keyless Entry and Alarm for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Normal Operation
The Smart Junction Box (SJB) monitors the voltage from the battery to determine if it goes above
or below specific thresholds and sets DTC B1317 in continuous memory if the SJB detects high
battery voltage above 15 volts on circuit SBB01 (RD).
- DTC B1317 (Battery Voltage High) - a continuous memory DTC that sets when the SJB detects
battery voltage above 15 volts on circuit SBB01 (RD).
This pinpoint test is intended to diagnose the following:
- Charging system concern
- SJB
PINPOINT TEST B: DTC B1317
NOTE: DTC B1317 may be stored in the module memory due to previous battery charging or
vehicle jump starting events.
------------------------------------------------- B1 CHECK FOR DTC B1317, B1676 OR P0563 SET IN
OTHER MODULES
- Ignition ON.
- Enter the following diagnostic mode on the scan tool: (All Modules) Self-Test.
- Retrieve the continuous memory DTCs from all modules.
- Is DTC B1317, B1676 or P0563 (PCM) set in more than one module?
Yes
REFER to Charging System to diagnose an overcharging condition.
No
GO to B2.
------------------------------------------------- B2 CHECK THE BATTERY VOLTAGE
- Turn off all interior/exterior lights and accessories.
- Start and run the engine at approximately 2,000 rpm for 3 minutes while monitoring the battery
voltage.
- Does the battery voltage rise to 15 volts or higher?
Yes
REFER to Charging System to diagnose an overcharging condition.
No
GO to B3.
------------------------------------------------- B3 RECHECK FOR DTC B1317
- Turn the engine off.
- Ignition ON.
- Enter the following diagnostic mode on the scan tool: SJB Self-Test.
- Clear the continuous memory DTCs.
- Carry out the SJB self-test.
- Is DTC B1317 present?
Yes
INSTALL a new SJB. REFER to Smart Junction Box (SJB) See: Power and Ground
Distribution/Power Distribution Module/Service and Repair. TEST the system for normal operation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7263
No
The system is operating normally at this time. The DTC may have been set previously during
battery charging or while jump starting the vehicle.
------------------------------------------------Pinpoint Test C: DTC B1318
Smart Junction Box (SJB)
Pinpoint Tests
Pinpoint Test C: DTC B1318
Refer to Wiring Diagram Set 117, Remote Keyless Entry and Alarm for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Normal Operation
The Smart Junction Box (SJB) monitors the voltage from the battery to determine if it goes above
or below specific thresholds and sets DTC B1318 in continuous memory if the SJB detects low
battery voltage below 10 volts on circuit SBB01 (RD).
- DTC B1318 (Battery Voltage Low) - a continuous memory DTC that sets when the SJB detects
battery voltage below 10 volts on circuit SBB01 (RD).
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- High circuit resistance
- SJB
PINPOINT TEST C: DTC B1318
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- C1 RECHECK THE SJB DTCs
- Ignition ON.
- Enter the following diagnostic mode on the scan tool: SJB Self-Test.
- Clear the DTCs. Repeat the SJB self-test.
- Is DTC B1318 still present?
Yes
GO to C2.
No
The system is operating normally at this time. The DTC may have been set previously during
battery charging or while jump starting the vehicle.
------------------------------------------------- C2 CHECK FOR CHARGING SYSTEM DTCs IN THE PCM
- Enter the following diagnostic mode on the scan tool: PCM Self-Test.
- Retrieve the continuous memory DTCs from the PCM.
- Is DTC P0620, P0625, P0626 or P065B set in the PCM?
Yes
REFER to Charging System.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7264
No
GO to C3.
------------------------------------------------- C3 CHECK THE BATTERY CONDITION AND STATE OF
CHARGE
- Ignition OFF.
- Check the battery condition and verify the battery is fully charged. Refer to Battery, Battery
Condition Test. See: Starting and Charging/Battery/Testing and Inspection/Pinpoint Tests
- Is the battery OK and fully charged?
Yes
GO to C4.
No
REFER to Charging System.
------------------------------------------------- C4 CHECK THE SJB VOLTAGE SUPPLY
- Measure and record the voltage at the battery.
- Disconnect: SJB C2280E.
- Ignition ON.
- Measure the voltage between the SJB C2280E-32, circuit SBB01 (RD), harness side and ground.
- Is the voltage within 0.2 volt of the recorded battery voltage?
Yes
GO to C5.
No
REPAIR the circuit for high resistance. CLEAR the DTC. REPEAT the self-test.
------------------------------------------------- C5 CHECK THE SJB GROUND CIRCUIT
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the SJB C2280E-22, circuit GD108 (BK/VT), harness side and
ground.
- Is the resistance less than 5 ohms?
Yes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7265
CONNECT the negative battery cable. GO to C6.
No
REPAIR the circuit for high resistance. CONNECT the negative battery cable. TEST the system for
normal operation.
------------------------------------------------- C6 CHECK FOR CORRECT SJB OPERATION
- Disconnect the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new SJB. REFER to Smart Junction Box (SJB) See: Power and Ground
Distribution/Power Distribution Module/Service and Repair. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector.
------------------------------------------------Pinpoint Test D: DTC U0155
Smart Junction Box (SJB)
Pinpoint Tests
Pinpoint Test D: DTC U0155
Normal Operation
- DTC U0155 (Lost Communication With Instrument Panel Cluster (IC) Control Module) - set by the
SJB whenever it receives invalid data from the Instrument Cluster (IC).
This pinpoint test is intended to diagnose the following:
- Module communication
- SJB
- IC
PINPOINT TEST D: DTC U0155
------------------------------------------------- D1 VERIFY CUSTOMER CONCERN
- Ignition ON.
- Verify that there is an observable symptom present.
- Is an observable symptom present?
Yes
GO to D2.
No
The system is operating normally at this time. The DTC may have been set due to high network
traffic or an intermittent fault condition.
-------------------------------------------------
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7266
D2 CHECK THE COMMUNICATION NETWORK
- Ignition ON.
- Enter the following diagnostic mode on the scan tool: Network Test.
- Carry out the network test.
Does the IC pass the network test?
Yes
GO to D3.
No
REFER to Information Bus.
------------------------------------------------- D3 RETRIEVE THE RECORDED DTCs FROM THE
SELF-TEST
- Check for recorded SJB DTCs from the self-test.
- Is DTC B1317 or B1318 recorded?
Yes
For DTC B1317, Go To Pinpoint Test b. See: Smart Junction Box (SJB)/Pinpoint Test B: DTC
B1317
For DTC B1318, Go To Pinpoint Test c. See: Smart Junction Box (SJB)/Pinpoint Test C: DTC
B1318
No
GO to D4.
------------------------------------------------- D4 RECHECK THE SJB DTCs
NOTE: If new modules were installed prior to the DTC being set, the module configuration may be
incorrectly set during Programmable Module Installation (PMI) or the PMI may not have been
carried out.
- Clear the DTCs. Repeat the SJB self-test.
- Is DTC U0155 still present?
Yes
GO to D5.
No
The system is operating correctly at this time. The DTC may have been set due to high network
traffic or an intermittent fault condition.
------------------------------------------------- D5 CHECK FOR DTC U0155 SET IN OTHER MODULES
- Clear all DTCs.
- Ignition OFF.
- Ignition ON.
- Wait 10 seconds.
- Enter the following diagnostic mode on the scan tool: Self-Test.
- Retrieve the continuous memory DTCs from all modules.
- Is DTC U0155 set in the ACM, DSM, audio DSP module or PAM?
Yes
INSTALL a new IC.
No
INSTALL a new SJB. REFER to Smart Junction Box (SJB) See: Power and Ground
Distribution/Power Distribution Module/Service and Repair.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7267
------------------------------------------------Pinpoint Test E: DTC U0164
Smart Junction Box (SJB)
Pinpoint Tests
Pinpoint Test E: DTC U0164
Normal Operation
- DTC U0164 (Lost Communication With HVAC Control Module (EATC)) - set by the Smart
Junction Box (SJB) if data messages received from the (module name) over the (network name)
are missing for (insert specified time).
This pinpoint test is intended to diagnose the following:
- Module communication
- SJB
- HVAC module
PINPOINT TEST E: DTC U0164
------------------------------------------------- E1 VERIFY CUSTOMER CONCERN
- Ignition ON.
- Verify that there is an observable symptom present.
- Is an observable symptom present?
Yes
GO to E2.
No
The system is operating normally at this time. The DTC may have been set due to high network
traffic or intermittent fault condition.
------------------------------------------------- E2 CHECK THE COMMUNICATION NETWORK
- Ignition ON.
- Enter the following diagnostic mode on the scan tool: Network Test.
- Carry out the network test.
Does the (insert sending module name) pass the network test?
Yes
GO to E3.
No
REFER to Information Bus.
------------------------------------------------- E3 RETRIEVE THE RECORDED DTCs FROM THE
SELF-TEST
- Check for recorded SJB DTCs from the self-test.
- Is DTC B1317 or B1318 recorded?
Yes
For DTC B1317, Go To Pinpoint Test b. See: Smart Junction Box (SJB)/Pinpoint Test B: DTC
B1317
For DTC B1318, Go To Pinpoint Test c. See: Smart Junction Box (SJB)/Pinpoint Test C: DTC
B1318
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 7268
No
GO to E4.
------------------------------------------------- E4 RECHECK THE SJB DTCs
NOTE: If new modules were installed prior to the DTC being set, the module configuration may be
incorrectly set during Programmable Module Installation (PMI) or the PMI may not have been
carried out.
- Clear the DTCs. Repeat the SJB self-test.
- Is DTC U0164 still present?
Yes
INSTALL a new HVAC module. TEST the system for normal operation. REPEAT the SJB self-test.
If DTC U0164 is still present, INSTALL a new SJB. REFER to Smart Junction Box (SJB) See:
Power and Ground Distribution/Power Distribution Module/Service and Repair.
No
The system is operating correctly at this time. The DTC may have been set due to high network
traffic or intermittent fault condition.
-------------------------------------------------
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module >
Component Information > Locations > Page 7273
Auxiliary Step / Running Board Module: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module >
Component Information > Locations > Page 7274
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module >
Component Information > Locations > Page 7275
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Locations > Running Board Motor, Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Locations > Running Board Motor, Left > Page 7280
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Diagrams > Running Board Motor, Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Diagrams > Running Board Motor, Left > Page 7283
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Diagrams > Page 7284
Auxiliary Step / Running Board Motor: Service and Repair
Power Running Board (PRB) Motor
NOTE: Mountaineer shown, Explorer similar.
NOTE: RH shown, LH similar.
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.
4. Remove the wedge screw and wedge. Note orientation for reinstallation.
- To install, tighten to 8 Nm (71 lb-in).
5. Remove the PRB motor splash shield screws and remove the splash shield.
6. Remove the 3 bolts and PRB motor.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Diagrams > Page 7285
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
NOTE: 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.
NOTE: Illustration is not vehicle specific.
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Procedures > Page 7292
Front Bumper Cover / Fascia: Removal and Replacement
Bumper Cover - Front
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.
Mountaineer
10. Remove the bumper cover upper screws.
11. Rotate the bottom of the front bumper cover upward.
12. Apply downward pressure to the top of the front bumper cover to release the 3 locking tabs.
All vehicles
13. Remove the front bumper cover.
14. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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.
NOTE: 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.
NOTE: Illustration is not vehicle specific.
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair > Procedures > Page 7298
Rear Bumper Cover / Fascia: Removal and Replacement
Bumper Cover - Rear, Explorer
Removal and Installation
1. Remove the tail lamp assemblies.
2. Remove the 2 rear bumper cover bracket bolts.
- To install, tighten to 11 Nm (97 lb-in).
3. Remove the 9 bumper cover pin-type retainers.
4. Disconnect the rear parking aid sensor electrical connector, if equipped.
5. NOTICE: To avoid damaging the rear bumper cover, do not twist the cover when removing.
Remove the bumper cover.
- Lift the outer corners upward and pull the bumper cover straight up and out.
6. Transfer components as necessary.
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair
Cowl Moulding / Trim: Service and Repair
Cowl Panel Grille
1. Remove the wiper pivot arms.
NOTICE: To avoid breaking the retaining clips on the cowl panel, do not pull up on the rear of the
cowl panel.
2. Pry up on the front of the cowl panel to release it from the retaining clips.
3. Remove the cowl panel grille.
4. Separate the left cowl panel from the right cowl panel by releasing the retaining clips.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Exterior Front Door Handle
Front Door Exterior Handle: Service and Repair Exterior Front Door Handle
Exterior Front Door Handle
Removal and Installation
1. Remove the front door trim panel.
2. Position the watershield aside.
3. Remove the screw and the energy absorbing foam pad.
4. If equipped, disconnect the door lock cylinder actuating rod.
5. Open the clip and disconnect the exterior front door handle actuating rod.
6. Remove the 2 exterior front door handle nuts.
- To install, tighten to 9 Nm (80 lb-in).
7. Remove the exterior front door handle.
8. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Exterior Front Door Handle > Page 7311
Front Door Exterior Handle: Service and Repair Front Door Handles, Locks and Latches Exploded View
Front Door Handles, Locks and Latches - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 Handles, Locks and Latches - Exploded View
Front Door Interior Handle: Service and Repair Front Door Handles, Locks and Latches - Exploded
View
Front Door Handles, Locks and Latches - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 Handles, Locks and Latches - Exploded View
> Page 7316
Front Door Interior Handle: Service and Repair Interior Door Handle - Front
Interior Door Handle - Front
Removal and Installation
1. Remove the front door trim panel.
2. Remove the 3 screws and the interior front door handle.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System
Information > Adjustments
Front Door Hinge: Adjustments
Door Alignment
Front and rear door
1. Depower the Supplemental Restraint System (SRS). For additional information, refer to Air Bag
Systems.
2. Remove the door latch striker plate.
Front door in and out, up and down adjustment
3. NOTE: The bolts securing the 2 hinge halves together are not to be removed or serviced.
Remove the hinge-to-door or hinge-to-body bolts when
removing or adjusting the front or rear doors.
NOTE: Driver side shown, passenger side similar.
Loosen, but do not remove, the front door hinge-to-front door fasteners enough to allow door
adjustment.
Front door fore, aft and tilt adjustment
NOTE: Driver side shown, passenger side similar.
4. Loosen, but do not remove, the upper front door hinge-to-body fasteners enough to allow door
adjustment.
5. If adjusting the driver side, remove the hood release lever.
1. Remove the screw.
2. Position the hood release lever.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System
Information > Adjustments > Page 7320
6. Remove the front door scuff plate.
7. Partially remove the front door weatherstrip.
8. Remove the lower cowl trim panel.
1. Remove the pin-type retainer.
2. Remove the lower cowl trim panel.
9. If adjusting the driver side, remove the hood release mechanism.
1. Remove the screw.
2. Position the hood release mechanism.
10. Disconnect the ground wires.
11. Position the weather shield and loosen, but do not remove, the front door lower hinge nut.
12. Loosen, but do not remove, the lower front door hinge-to-body fasteners enough to allow door
adjustment.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System
Information > Adjustments > Page 7321
Rear door fore, aft and tilt adjustment
13. Remove the front door scuff plate.
14. Remove the rear door scuff plate.
15. Remove the lower B-pillar trim panel.
16. Remove the front safety belt retractor.
- Remove the front safety belt retractor bolt. To install, tighten to 40 Nm (30 lb-ft).
- Remove the safety belt retractor and position aside.
17. Loosen, but do not remove, the rear door hinge-to-body fasteners enough to allow door
adjustment.
Rear door in and out, up and down adjustment
18. Loosen, but do not remove, the rear door hinge-to-rear door fasteners enough to allow door
adjustment.
Front and rear door
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System
Information > Adjustments > Page 7322
19. Adjust the door.
20. Tighten the door fasteners.
- Tighten the front door hinge-to-front door fasteners to 30 Nm (22 lb-ft).
- Tighten the front door hinge-to-body fasteners to 30 Nm (22 lb-ft).
- Tighten the front door lower hinge nut to 30 Nm (22 lb-ft).
- Tighten the rear door hinge-to-rear door fasteners to 30 Nm (22 lb-ft).
- Tighten the rear door hinge-to-body fasteners to 30 Nm (22 lb-ft).
21. Reassemble the system.
22. Install and adjust the door striker as necessary.
- Tighten the door latch striker plate screws to 25 Nm (18 lb-ft).
23. Repower the SRS. For additional information, refer to Air Bag Systems.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Adjustments
Front Door Latch: Adjustments
Door Handle to Latch Rod Adjustment
NOTE: An incorrectly adjusted exterior door handle can cause a loose handle, rattle noise, door
hard to open from the outside door handle, or the outside door handle to not sit flush in the closed
position.
NOTE: Prior to carrying out the adjustment procedure, the door latch, exterior door handle, and
linkages must be installed on the door.
1. Raise the door glass to the full-up position.
2. Remove the door trim panel.
3. Position the watershield aside.
4. Open the clip and disconnect the exterior door handle actuating rod.
5. Position the actuating rod and latch actuating lever in a neutral position.
6. NOTE: Do not push up or pull down on the actuating rod or latch actuating lever.
Reinstall the exterior door handle actuating rod back into the clip.
7. Close the clip and test the system to make sure that the exterior door handle is operating
correctly.
8. Reseal the watershield.
9. Install the door trim panel.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Service and Repair > Procedures
Front Door Latch: Procedures
Latch Lubrication
1. Open the door.
2. Using a screwdriver, fully close the latch (two clicks).
3. Spray the multi-purpose grease into the opening on the door latch for approximately 5 seconds.
4. Open the latch using either the interior or exterior door handle.
5. Open and close the door several times to circulate the lubricant inside the latch.
6. Wipe off any excess grease.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Service and Repair > Procedures > Page 7328
Front Door Latch: Removal and Replacement
Front Door Handles, Locks and Latches - Exploded View
Front Door Handles, Locks and Latches - Exploded View
1. For additional information, refer to the procedures.
Front Door Latch
Front Door Latch
Removal and Installation
1. Remove the front door trim panel.
2. Position the watershield aside.
3. NOTE: Slide the foam insulating block forward to release the 2 clips.
Remove the screw and the energy absorbing foam pad.
4. Release the interior door handle actuating cable locator from the door frame.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Service and Repair > Procedures > Page 7329
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 (106 lb-in).
10. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Service and Repair
Front Door Panel: Service and Repair
Door Trim Panel - Front
Removal and Installation
1. Remove the front door trim panel handle bezel cover.
2. Remove the front door trim panel handle bezel screws.
3. Remove the front door trim panel lower screws.
NOTICE: 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 (V6-4.0L (2009))
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 > Glass, Frames and Mechanisms Exploded View, Front Door
Front Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Front Door
Glass, Frames and Mechanisms - Exploded View, Front Door
NOTE: LH shown, RH similar.
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Glass, Frames and Mechanisms Exploded View, Front Door > Page 7338
Front Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Front
Door Glass Top Run - Front
Removal and Installation
NOTE: For LH front only, the front window motor must be initialized whenever the front window
motor is removed from the window regulator drum housing, a new window regulator is installed, a
new top run is installed or for any operation in which grease or lubricants are applied to the window
regulator or glass run.
1. Remove the front door window glass. For additional information, refer to Window Glass - Front
Door See: Service and Repair/Window Glass Front Door.
2. Remove the exterior moulding.
3. Remove the front door glass top run channel assembly bolt.
- To install, tighten to 12 Nm (106 lb-in).
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.
- For LH front window only, initialize the LH front window motor. For additional information, refer to
Window Motor Initialization - Front See: Windows and Glass/Windows/Service and Repair/Window
Motor Initialization - Front.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door
Front Door Window Motor: Service and Repair Glass, Frames and Mechanisms - Exploded View,
Front Door
Glass, Frames and Mechanisms - Exploded View, Front Door
NOTE: LH shown, RH similar.
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 7343
Front Door Window Motor: Service and Repair Window Regulator Motor - Front Door
Window Regulator Motor - Front Door
Removal and Installation
NOTE: For LH front only, the front window motor must be initialized whenever the front window
motor is removed from the window regulator drum housing, a new window regulator is installed, a
new top run is installed or for any operation in which grease or lubricants are applied to the window
regulator or glass run.
1. Remove the front door window regulator. For additional information, refer to Window Regulator Front Door See: Front Door Window
Regulator/Service and Repair/Window Regulator - Front Door.
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.
- For LH front window only, initialize the LH front window motor. For additional information, refer to
Window Motor Initialization - Front See: Windows and Glass/Windows/Service and Repair/Window
Motor Initialization - Front.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door
Front Door Window Regulator: Service and Repair Glass, Frames and Mechanisms - Exploded
View, Front Door
Glass, Frames and Mechanisms - Exploded View, Front Door
NOTE: LH shown, RH similar.
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door >
Page 7348
Front Door Window Regulator: Service and Repair Window Regulator - Front Door
Window Regulator - Front Door
Removal and Installation
NOTE: For LH front only, the front window motor must be initialized whenever the front window
motor is removed from the window regulator drum housing, a new window regulator is installed, a
new top run is installed or for any operation in which grease or lubricants are applied to the window
regulator or glass run.
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. NOTICE: 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.
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.
- For LH front window only, initialize the LH front window motor. For additional information, refer to
Window Motor Initialization - Front See: Windows and Glass/Windows/Service and Repair/Window
Motor Initialization - Front.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Exterior Rear Door Handle
Rear Door Exterior Handle: Service and Repair Exterior Rear Door Handle
Exterior Rear Door Handle
Removal and Installation
1. Remove the rear door trim panel.
2. Position the watershield aside.
3. Open the clip and disconnect the exterior rear door handle actuating rod.
4. Remove the 2 nuts and the exterior rear door handle.
- To install, tighten to 9 Nm (80 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Exterior Rear Door Handle > Page 7355
Rear Door Exterior Handle: Service and Repair Rear Door Handles, Locks and Latches - Exploded
View
Rear Door Handles, Locks and Latches - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear
Door Interior Handle > System Information > Service and Repair
Rear Door Interior Handle: Service and Repair
Interior Door Handle - Rear
Removal and Installation
1. Remove the rear door trim panel.
2. Remove the 3 interior rear door handle screws and the interior rear door handle.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Adjustments
Rear Door Latch: Adjustments
Door Handle to Latch Rod Adjustment
NOTE: An incorrectly adjusted exterior door handle can cause a loose handle, rattle noise, door
hard to open from the outside door handle, or the outside door handle to not sit flush in the closed
position.
NOTE: Prior to carrying out the adjustment procedure, the door latch, exterior door handle, and
linkages must be installed on the door.
1. Raise the door glass to the full-up position.
2. Remove the door trim panel.
3. Position the watershield aside.
4. Open the clip and disconnect the exterior door handle actuating rod.
5. Position the actuating rod and latch actuating lever in a neutral position.
6. NOTE: Do not push up or pull down on the actuating rod or latch actuating lever.
Reinstall the exterior door handle actuating rod back into the clip.
7. Close the clip and test the system to make sure that the exterior door handle is operating
correctly.
8. Reseal the watershield.
9. Install the door trim panel.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Service and Repair > Procedures
Rear Door Latch: Procedures
Latch Lubrication
1. Open the door.
2. Using a screwdriver, fully close the latch (two clicks).
3. Spray the multi-purpose grease into the opening on the door latch for approximately 5 seconds.
4. Open the latch using either the interior or exterior door handle.
5. Open and close the door several times to circulate the lubricant inside the latch.
6. Wipe off any excess grease.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Service and Repair > Procedures > Page 7364
Rear Door Latch: Removal and Replacement
Rear Door Handles, Locks and Latches - Exploded View
Rear Door Handles, Locks and Latches - Exploded View
1. For additional information, refer to the procedures.
Rear Door Latch
Rear Door Latch
Removal and Installation
1. Remove the rear door trim panel.
2. Position the watershield aside.
3. Release the interior door handle actuating cable locator from the door frame.
4. Open the clip and disconnect the exterior handle actuating rod.
5. Disconnect the rear door ajar switch and rear door lock actuator electrical connectors.
6. Remove the 3 rear door latch screws.
- To install, tighten to 12 Nm (106 lb-in).
7. Release the rear door push button rod from the door frame retainer.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Service and Repair > Procedures > Page 7365
8. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Service and Repair
Rear Door Panel: Service and Repair
Door Trim Panel - Rear
Explorer/Mountaineer
Explorer Sport Trac
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Service and Repair > Page 7369
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. NOTICE: To avoid damaging the trim panel, do not pull the bottom of the panel outward.
Remove the rear door trim panel by lifting upward on the armrest to disengage the panel clips.
7. Disconnect the electrical connectors.
8. Disconnect the rod cable from the rear door trim panel.
9. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Door Glass Top Run - Rear
Rear Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Rear
Door Glass Top Run - Rear
Removal and Installation
1. Remove the rear door window glass. For additional information, refer to Window Glass - Rear
Door See: Service and Repair/Window Glass Rear Door.
2. Remove the exterior moulding.
3. Remove the rear door glass top run assembly bolt.
- To install, tighten to 12 Nm (106 lb-in).
4. Remove the rear door glass top run channel assembly.
- Remove the rear door glass top run channel assembly through the top opening of the rear door.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 > Door Glass Top Run - Rear >
Page 7375
Rear Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Rear Door
Glass, Frames and Mechanisms - Exploded View, Rear Door
NOTE: Explorer shown, Explorer Sport Trac similar.
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door
Rear Door Window Motor: Service and Repair Glass, Frames and Mechanisms - Exploded View,
Rear Door
Glass, Frames and Mechanisms - Exploded View, Rear Door
NOTE: Explorer shown, Explorer Sport Trac similar.
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door > Page 7380
Rear Door Window Motor: Service and Repair Window Regulator Motor - Rear Door
Window Regulator Motor - Rear Door
Removal and Installation
1. Remove the interior moulding.
2. Remove the rear door trim panel and weather shield.
3. Remove the 3 window regulator motor bolts.
- To install, tighten to 7 Nm (62 lb-in).
4. Remove the window regulator motor.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door
Rear Door Window Regulator: Service and Repair Glass, Frames and Mechanisms - Exploded
View, Rear Door
Glass, Frames and Mechanisms - Exploded View, Rear Door
NOTE: Explorer shown, Explorer Sport Trac similar.
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door > Page 7385
Rear Door Window Regulator: Service and Repair Window Regulator - Rear Door
Window Regulator - Rear Door
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. NOTICE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Switch
> Component Information > Locations
Power Sliding Door Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Switch
> Component Information > Locations > Page 7390
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Switch
> Component Information > Locations > Page 7391
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Switch
> Component Information > Locations > Page 7392
Power Sliding Door Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Switch
> Component Information > Locations > Page 7393
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and
Repair
Fuel Door: Service and Repair
Fuel Filler Door Cup Bezel
Removal
1. NOTICE: Apply tape around the circumference of the fuel filler door. Failure to follow this
direction may result in damage to the vehicle.
Remove the fuel filler door screws and reposition the fuel filler door.
2. Using a 90 degree pick tool, release the upper RH fuel filler door cup bezel clip from the body.
3. Using a non-marring body tool, prevent the fuel filler door cup bezel from re-attaching to the
body.
4. Using a 90 degree pick tool, release the bottom RH fuel filler door cup bezel clip from the body.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and
Repair > Page 7397
5. Pull outward and upward to remove the fuel filler door cup bezel from the body.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Service and Repair > Hood Latch
Hood Latch: Service and Repair Hood Latch
Hood Latch
Removal and Installation
NOTE: Mark the position of the hood latch prior to removing the hood latch bolts to aid positioning
during installation.
1. Remove the 2 hood latch bolts.
- To install, tighten to 12 Nm (106 lb-in).
2. Disconnect the hood latch release cable from the hood latch and remove the latch.
3. To install, reverse the removal procedure.
- Check the latch adjustment to make sure the latch was installed and aligned correctly.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Service and Repair > Hood Latch > Page 7403
Hood Latch: Service and Repair Hood Latch and Components - Exploded View
Hood Latch and Components - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component
Information > Service and Repair > Hood Latch and Components - Exploded View
Hood Latch Release: Service and Repair Hood Latch and Components - Exploded View
Hood Latch and Components - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component
Information > Service and Repair > Hood Latch and Components - Exploded View > Page 7408
Hood Latch Release: Service and Repair Hood Latch Release Handle
Hood Latch Release Handle
Removal and Installation
1. Remove the hood latch. For additional information, refer to Hood Latch See: Hood Latch/Service
and Repair/Hood Latch.
2. Remove the screw and the hood latch release handle.
3. Remove the pin-type retainer and the LH A-pillar lower trim panel.
4. Remove the hood latch release cable assembly screw.
5. Release the hood latch release cable from the 4 cable locators and remove the cable.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
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.
Remove the liftgate window glass struts.
- To avoid breaking the liftgate window glass, disconnect the liftgate window glass struts from the
liftgate window glass before disconnecting the liftgate window glass struts from the rear liftgate.
5. Remove the 2 liftgate hinge-to-glass screws.
- Apply threadlock into the liftgate window glass hinge-to-glass bolt hole, making sure that the
threadlock is on the threads.
- To install, tighten to 10 Nm (89 lb-in).
6. With the help of an assistant, remove the liftgate window glass.
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Locations > Liftgate Glass Actuator
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Locations > Liftgate Glass Actuator > Page 7417
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Diagrams > Liftgate Glass Actuator
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Diagrams > Liftgate Glass Actuator > Page 7420
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Diagrams > Page 7421
Power Trunk / Liftgate Lock Actuator: Service and Repair
Liftgate Latch Actuator
Removal and Installation
1. Remove the liftgate latch. For additional information, refer to Liftgate Latch See: Trunk / Liftgate
Latch/Service and Repair/Liftgate Latch.
2. Release the locking tab and remove the liftgate latch actuator.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Page 7425
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Page 7426
Power Trunk / Liftgate Lock Switch: Service and Repair
Liftgate Window Latch Actuator
Removal and Installation
1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See:
Trunk / Liftgate Latch/Service and
Repair/Liftgate Window Latch.
2. Remove the 3 screws and the liftgate window latch actuator.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Ajar Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Ajar Switch >
Component Information > Locations > Page 7430
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View
Trunk / Liftgate Handle: Service and Repair Liftgate Handle, Lock and Latch - Exploded View
Liftgate Handle, Lock and Latch - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 7435
Trunk / Liftgate Handle: Service and Repair Liftgate Release Handle
Liftgate Release Handle
Removal and Installation
1. Remove the liftgate trim panel.
2. Position the watershield aside.
3. Disconnect the liftgate release handle actuating rod.
4. Remove the 2 liftgate release handle screws.
5. Remove the liftgate release handle.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim
Panel > Component Information > Service and Repair
Trunk / Liftgate Interior Trim Panel: Service and Repair
Liftgate Trim Panel
Removal and Installation
1. Remove the 2 liftgate grab handle screws.
2. Remove the liftgate grab handle.
3. NOTICE: To avoid damaging the trim panel, do not pull the bottom of the panel outward.
Lift the liftgate trim panel by lifting upward to disengage the clips and remove the panel.
- Disconnect the liftgate trim panel electrical connector.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View
Trunk / Liftgate Latch: Service and Repair Liftgate Handle, Lock and Latch - Exploded View
Liftgate Handle, Lock and Latch - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 7443
Trunk / Liftgate Latch: Service and Repair Liftgate Latch
Liftgate Latch
Removal and Installation
1. Remove the liftgate trim panel.
2. Position the watershield aside.
3. Disconnect the liftgate release handle actuating rod.
4. Disconnect the liftgate latch actuator and the liftgate ajar switch electrical connectors.
5. Remove the 3 liftgate latch screws and remove the latch.
- To install, tighten to 12 Nm (106 lb-in).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 7444
Trunk / Liftgate Latch: Service and Repair Liftgate Window Latch
Liftgate Window Latch
Removal and Installation
1. Remove the liftgate trim panel.
2. Position the watershield aside.
3. Disconnect the liftgate window actuator and liftgate window ajar switch electrical connectors.
4. Remove the 4 screws and the liftgate window latch.
- To install, tighten to 12 Nm (106 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock > System
Information > Service and Repair
Trunk / Liftgate Lock: Service and Repair
Liftgate Handle, Lock and Latch - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information >
Service and Repair
Cowl Moulding / Trim: Service and Repair
Cowl Panel Grille
1. Remove the wiper pivot arms.
NOTICE: To avoid breaking the retaining clips on the cowl panel, do not pull up on the rear of the
cowl panel.
2. Pry up on the front of the cowl panel to release it from the retaining clips.
3. Remove the cowl panel grille.
4. Separate the left cowl panel from the right cowl panel by releasing the retaining clips.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service
and Repair > Fender Splash Shield
Front Fender Liner: Service and Repair Fender Splash Shield
Fender Splash Shield
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.
5. Remove the front splash shield screws.
6. Remove the front splash shield pin-type retainers.
7. Remove the front splash shield.
8. Remove the front fender splash shield.
9. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service
and Repair > Fender Splash Shield > Page 7458
Front Fender Liner: Service and Repair Front End Body Panels - Exploded View
Front End Body Panels - Exploded View
Explorer/Explorer Sport Trac
Mountaineer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service
and Repair > Fender Splash Shield > Page 7459
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 7464
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.
NOTICE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 7465
Body Support - Front End Sheet Metal (FESM)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 7466
Body Support - No. 1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 7467
Body Support - No. 2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 7468
Body Support - No. 3 (Explorer/Mountaineer ONLY)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 7469
Body Support - No. 3 (Explorer Sport Trac ONLY)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 7470
Body Support - No. 4 (Explorer/Mountaineer ONLY)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications
Cross-Member: Specifications
Torque Specifications
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 a hoist. 2. Remove the 4 transfer case skid plate
bolts and remove the transfer case skid plate.
- To install, tighten to 15 Nm (133 lb-in).
3. NOTE: Explorer/Mountaineer shown, Explorer Sport Trac similar.
Remove the heat shield bolt from the RH heat shield.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair >
Transmission Support Crossmember > Page 7476
- To install, tighten to 18 Nm (159 lb-in).
4. Remove the heat shield bolt from the LH heat shield.
- To install, tighten to 18 Nm (159 lb-in).
5. Support the transmission with a suitable jack. 6. Remove the 2 transmission mount nuts.
- To install, tighten to 90 Nm (66 lb-ft).
7. Remove the 6 transmission crossmember lower bolts.
- To install, tighten to 80 Nm (59 lb-ft).
8. NOTE: Tighten the nut side of the joint.
Remove the 2 upper nuts and 2 bolts from the transmission crossmember.
- To install, tighten to 143 Nm (105 lb-ft).
9. Remove the transmission crossmember.
10. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair >
Transmission Support Crossmember > Page 7477
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. For additional information, Vehicle Jacking
and Lifting. 2. Remove the 4 crossmember bolts. 3. Remove the 4 crossmember nuts.
- To install, tighten to 103 Nm (76 lb-ft).
4. Remove the 1B crossmember. 5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
7481
EXPLORER/MOUNTAINEER TEMPLATE # 1, LEFT HAND INNER SIDE VIEW, RIGHT HAND
SYMMETRICALLY OPPOSITE
5. Drill 18 mm (0.688 in) diameter holes for the inboard and outboard attachments to each frame
rail.
- For the inboard side use Explorer/Mountaineer template No. 2.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
7482
EXPLORER/MOUNTAINEER TEMPLATE # 2, LEFT HAND INNER SIDE VIEW, RIGHT HAND
INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER
- For the outboard side use Explorer/Mountaineer template No. 3.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
7483
EXPLORER/MOUNTAINEER TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND
INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER
Explorer Sport Trac
6. Cut the rear rails vertically at least 10-18 mm (0.39-0.70 in) behind the rear body/box mount leg.
- Use Sport Trac template No. 1.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
7484
SPORT TRAC TEMPLATE # 1, LEFT HAND INNER SIDE VIEW, RIGHT HAND
SYMMETRICALLY OPPOSITE
7. Drill 18 mm (0.688 in) diameter holes for the inboard and outboard attachments to each frame
rail.
- Use Sport Trac Template No. 2.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
7485
SPORT TRAC TEMPLATE # 2, LEFT HAND INNER SIDE VIEW, RIGHT HAND INNER
SYMMETRICALLY OPPOSITE TO LEFT HAND INNER
- Use Sport Trac template No. 3.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
7486
SPORT TRAC TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND INNER
SYMMETRICALLY OPPOSITE TO LEFT HAND INNER
All vehicles
8. Deburr 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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
7487
Insert the new trailer hitch crossmember assembly into the frame.
12. Hand-start all 8 bolts into the weld nuts in the hitch brackets. 13. Tighten the inboard bolts.
- Tighten to 235 Nm (174 lb-ft).
14. Tighten the outboard bolts.
- Tighten to 235 Nm (174 lb-ft).
15. Install the trailer wiring harness. 16. Install the rear bumper cover. 17. Install the spare tire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Page
7491
Trailer Towing Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Page
7492
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille
Opening Panel
Grille: Service and Repair Radiator Grille Opening Panel
Radiator Grille Opening Panel
Removal and Installation
1. Remove the headlamp assemblies.
2. Remove the front bumper cover.
3. Remove the 5 grille panel deflector pin-type retainers.
4. Remove the grille panel deflector.
5. Remove the 8 grille opening panel bolts.
- To install, tighten to 9 Nm (80 lb-in).
6. Remove the grille opening panel center bolt.
- To install, tighten to 9 Nm (80 lb-in).
7. Remove the grille opening panel.
8. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille
Opening Panel > Page 7497
Grille: Service and Repair Radiator Grille
Radiator Grille - Explorer, Explorer Sport Trac
NOTE: For Mountaineer, refer to Radiator Grille - Mountaineer See: .
Removal and Installation
1. Remove the front bumper cover.
2. Remove the 2 grille-to-bumper cover screws.
3. Remove the front bumper isolator and absorber.
1. Remove the 2 pushpins.
2. Remove the 2 nuts.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille
Opening Panel > Page 7498
4. Remove the 4 scrivets.
5. Carefully release the 14 clips and remove the grille assembly from the bumper cover.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Console - Overhead
Console: Service and Repair Console - Overhead
Console - Overhead
Overhead Console With Roof Opening Panel
Overhead Console Without Roof Opening Panel
Removal and Installation
Vehicles with roof opening panel
1. Pull the overhead console downward to release the retaining clips.
Vehicles without roof opening panel
2. Open the overhead console garage door opener storage compartment.
3. Remove the overhead console screw.
All vehicles
4. Remove the overhead console.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Console - Overhead > Page 7504
5. Disconnect the electrical connectors.
6. To install, reverse the removal procedure.
- On vehicles with a roof opening panel, make sure to align the overhead console retaining clips to
the adjacent retaining clip holes.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Console - Overhead > Page 7505
Console: Service and Repair Console - Front, Floor
Console - Front, Floor
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.
- Disconnect the electrical connector.
8. Disconnect the front floor console electrical connectors.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Console - Overhead > Page 7506
13. Remove the front floor console.
- Pull the front floor console toward the rear of the vehicle.
14. To install, reverse the removal procedures.
- Make sure to align the trim panel retaining clips to the adjacent retaining clip holes.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Console - Overhead > Page 7507
Console: Service and Repair Console - Rear, Floor
Console - Rear, Floor
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. NOTICE: 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. NOTICE: 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 (V6-4.0L (2009))
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
Depowering Procedure
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
may result in serious personal injury.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
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(R) and
cause serious personal injury or death.
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (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 RCM fuse 17 (10A) from the SJB.
For additional information, refer to the Wiring Diagram.
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 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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 7513
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 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 an 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 (V6-4.0L (2009))
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 7514
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Deactivation and Reactivation
Supplemental Restraint System (SRS) Deactivation and Reactivation
Deactivation
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
may result in serious personal injury.
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.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
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.
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
All vehicles
1. Turn all vehicle accessories OFF.
2. Turn the ignition switch OFF.
3. At the Smart Junction Box (SJB), located below the LH side of the instrument panel, remove the
cover and RCM fuse 17 (10A) from the SJB. For
additional information, refer to the Wiring Diagrams.
4. Turn the ignition switch 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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 7515
7. Remove the 2 driver air bag module bolts (1 shown).
8. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag
module.
9. Open and lower the glove compartment door.
10. Detach the wiring retainer, remove the 4 bolts and passenger air bag module heat shield.
11. NOTE: The canister vent and adaptive tether do not require deactivation.
Disconnect the LH side passenger air bag module electrical connector.
12. Under the rear of the passenger seat, detach the passenger seat side air bag module electrical
connector from the seat track bracket. Disengage the
passenger seat side air bag module electrical connector locking clip, release the tab and
disconnect the passenger seat side air bag module electrical connector.
Explorer and Mountaineer vehicles
13. Release and position aside the passenger side C-pillar trim panel.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 7516
14. Disconnect the passenger side safety canopy module electrical connector.
15. Release and position aside the driver side C-pillar trim panel.
16. Disconnect the driver side safety canopy module electrical connector.
Explorer Sport Trac vehicles
17. Remove the driver and passenger side upper C-pillar trim panels.
18. Disconnect the passenger side safety canopy module electrical connector.
19. Disconnect the driver side safety canopy module electrical connector.
All vehicles
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 7517
20. Under driver seat, the rear of the slide and disengage the driver seat side air bag module
electrical connector locking clip, release the tab and
disconnect the driver seat side air bag module electrical connector.
21. Install the RCM fuse 17 (10A) to the SJB.
22. 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. Connect the driver seat side air bag module electrical connector and engage the seat side air
bag electrical connector locking clip.
Explorer Sport Trac vehicles
4. Connect the driver side safety canopy module electrical connector.
5. Connect the passenger side safety canopy module electrical connector.
6. Install the driver and passenger upper C-pillar trim panels.
Explorer and Mountaineer vehicles
7. Connect the driver side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 7518
8. Install the driver side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
9. Connect the passenger side safety canopy module electrical connector.
10. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles
11. Connect the passenger seat side air bag module electrical connector and engage the seat side
air bag electrical connector locking clip. Attach the
passenger seat side air bag module electrical connector to the seat track bracket.
12. Connect the LH side passenger air bag module electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 7519
13. Install the passenger air bag module heat shield and 4 bolts. Attach the wiring retainer.
14. NOTICE: 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.
15. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
16. Turn the ignition switch from OFF to ON.
17. Install RCM fuse 17 (10A) to the SJB and install the cover.
18. 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.
19. 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 an 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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair
Headliner: Service and Repair
Headliner
Explorer/Mountaineer
NOTE: Headliner with roof opening panel shown, headliner without opening panel similar.
Explorer Sport Trac
NOTE: Headliner without roof opening panel shown, headliner with opening panel similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Page 7523
Explorer and Mountaineer only
1. If equipped, remove the rear entertainment system.
Explorer Sport Trac only
2. NOTE: The headliner is removed through the rear passenger door. To facilitate removal, the
front passenger seat must be removed.
Remove the front passenger seat.
All vehicles
3. Remove the overhead console.
4. Remove the A-pillar trim panel. For additional information, refer to A-Pillar Trim Panel See: Trim
Panel/Service and Repair/A-Pillar Trim Panel.
5. Position the B-pillar upper trim panel aside. For additional information, refer to B-Pillar Upper
Trim Panel See: Trim Panel/Service and
Repair/B-Pillar Upper Trim Panel.
Explorer and Mountaineer only
6. Remove the C-pillar trim panel. For additional information, refer to C-Pillar Trim Panel - Explorer,
Mountaineer See: Trim Panel/Service and
Repair/C-Pillar Trim Panel.
7. Remove the D-pillar trim panel. For additional information, refer to D-Pillar Trim Panel See: Trim
Panel/Service and Repair/D-Pillar Trim Panel.
Explorer Sport Trac
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Page 7524
8. Position the C-pillar upper trim panel aside. For additional information, refer to C-Pillar Upper
Trim Panel - Explorer Sport Trac .
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.
20. Disconnect all the electrical connectors.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Page 7525
All vehicles
21. Disconnect the electrical connector and the wiring pin-type retainers on the A-pillar.
22. NOTICE: 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. NOTICE: To prevent damaging the garment hanger retainer, use a 3/16-inch flat-blade
screwdriver to carry out this step.
NOTE: The garment hanger is shown without the roof sheet metal screw to show the metal retainer
clip. The metal retainer clip will remain engaged in the sheet metal after the garment hanger is
removed.
Remove the garment hangers.
1. Open the access door.
2. Insert the flat-blade screwdriver fully into the garment hanger slot.
3. Rotate the screwdriver 90 degrees so that the screwdriver spreads the metal retainer clip.
Remove the plastic garment hanger.
26. NOTE: The headliner is removed through the passenger rear door for Explorer Sport Trac.
Remove the headliner.
27. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical
Service Bulletins > Customer Interest for Sun Visor: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover Cracked
Sun Visor: Customer Interest Interior - Sun Visor Mirror Cover Cracked
TSB 09-2-9
02/09/09
SUN VISOR MIRROR COVER CRACKING - BUILT BETWEEN 1/212007 AND 11/3/2008
FORD: 2007-2009 Explorer Sport Trac, Explorer
MERCURY: 2007-2009 Mountaineer
ISSUE Some 2007-2009 Explorer, Mountaineer and Sport Trac vehicles equipped with camel color
sun visors built between 1/2/2007 and 11/3/2008 may exhibit a crack in the plastic at the sun visor
mirror cover hinge.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Replace all affected sun visors with new updated parts.
2. Remove the two (2) sun visor screws on the affected side and disconnect the electrical
connector.
3. To install, reverse the removal procedure.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
090209A 2007-2009 Explorer, 0.3 Hr.
Mountaineer, Sport Trac: Replace ONE Sun Visor (Do Not Use With 04104A)
090209B 2007-2009 Explorer, 0.4 Hr.
Mountaineer, Sport Trac: Replace BOTH Sun Visors (Do Not Use With 04104A)
DEALER CODING
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
7534
CONDITION
BASIC PART NO. CODE
7804104 D4
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Sun Visor: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover
Cracked
Sun Visor: All Technical Service Bulletins Interior - Sun Visor Mirror Cover Cracked
TSB 09-2-9
02/09/09
SUN VISOR MIRROR COVER CRACKING - BUILT BETWEEN 1/212007 AND 11/3/2008
FORD: 2007-2009 Explorer Sport Trac, Explorer
MERCURY: 2007-2009 Mountaineer
ISSUE Some 2007-2009 Explorer, Mountaineer and Sport Trac vehicles equipped with camel color
sun visors built between 1/2/2007 and 11/3/2008 may exhibit a crack in the plastic at the sun visor
mirror cover hinge.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Replace all affected sun visors with new updated parts.
2. Remove the two (2) sun visor screws on the affected side and disconnect the electrical
connector.
3. To install, reverse the removal procedure.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
090209A 2007-2009 Explorer, 0.3 Hr.
Mountaineer, Sport Trac: Replace ONE Sun Visor (Do Not Use With 04104A)
090209B 2007-2009 Explorer, 0.4 Hr.
Mountaineer, Sport Trac: Replace BOTH Sun Visors (Do Not Use With 04104A)
DEALER CODING
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 7540
CONDITION
BASIC PART NO. CODE
7804104 D4
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim - Exploded View
Trim Panel: Service and Repair Interior Trim - Exploded View
Interior Trim - Exploded View
Explorer and Mountaineer
Explorer Sport Trac
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim - Exploded View > Page 7545
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim - Exploded View > Page 7546
Trim Panel: Service and Repair A-Pillar Trim Panel
A-Pillar Trim Panel
Removal and Installation
1. Remove the 2 assist handle bolt covers.
2. Remove the 2 assist handle bolts.
- To install, tighten to 10 Nm (89 lb-in).
3. Remove the assist handle.
4. Position the door opening weatherstrip aside.
5. NOTE: The clip on the LH A-pillar trim panel must remain in the sheet metal. The clip comes off
the A-pillar trim panel when the panel is
removed.
Remove the A-pillar trim panel.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim - Exploded View > Page 7547
Trim Panel: Service and Repair B-Pillar Lower Trim Panel
B-Pillar Lower Trim Panel
Removal and Installation
1. Remove the front and rear door scuff plates.
2. Position the door opening weatherstrip aside.
3. Remove the B-pillar lower trim panel.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim - Exploded View > Page 7548
Trim Panel: Service and Repair B-Pillar Upper Trim Panel
B-Pillar Upper Trim Panel
Removal and Installation
1. Remove the B-pillar lower trim panel. For additional information, refer to B-Pillar Lower Trim
Panel See: 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.
5. Remove the B-pillar upper trim panel retaining clip from the upper left of the panel.
6. To install, reverse the removal procedure.
- Be sure the hole on the back of the B-pillar upper trim panel is seated over the safety belt D-ring
bolt.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim - Exploded View > Page 7549
Trim Panel: Service and Repair
Interior Trim - Exploded View
Interior Trim - Exploded View
Explorer and Mountaineer
Explorer Sport Trac
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim - Exploded View > Page 7550
1. For additional information, refer to the procedures.
A-Pillar Trim Panel
A-Pillar Trim Panel
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim - Exploded View > Page 7551
6. To install, reverse the removal procedure.
B-Pillar Lower Trim Panel
B-Pillar Lower Trim Panel
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
Removal and Installation
1. Remove the B-pillar lower trim panel. For additional information, refer to B-Pillar Lower Trim
Panel See: 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.
5. Remove the B-pillar upper trim panel retaining clip from the upper left of the panel.
6. To install, reverse the removal procedure.
- Be sure the hole on the back of the B-pillar upper trim panel is seated over the safety belt D-ring
bolt.
C-Pillar Trim Panel
C-Pillar Trim Panel - Explorer, Mountaineer
Removal and Installation
Second row bucket
1. Position the second row seat to the forward position.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim - Exploded View > Page 7552
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.
Cab Rear Trim Panel
Cab Rear Trim Panel
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.
Remove the rear trim panel.
4. To install, reverse the removal procedures.
Cowl Side Trim Panel
Cowl Side Trim Panel
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim - Exploded View > Page 7553
4. Remove the cowl trim panel.
1. Remove the pin-type retainer.
2. Remove the cowl trim panel.
All vehicles
5. To install, reverse the removal procedure.
D-Pillar Trim Panel
D-Pillar Trim Panel
Removal and Installation
Vehicles with third row seating
1. Remove the rear cargo management system.
- Remove the screw.
- Remove the pushpin.
- Remove the system.
2. Remove the D-pillar lower safety belt anchor bolt.
- To install, tighten to 40 Nm (30 lb-ft).
All vehicles
3. Position the liftgate opening weatherstrip aside.
4. Remove the rear upper headliner trim panel.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim - Exploded View > Page 7554
5. Remove the D-pillar trim panel.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component
Information > Service and Repair
Utility Storage Compartment: Service and Repair
Instrument Panel - Exploded View
NOTE: Explorer/Explorer Sport Trac shown, Mountaineer similar.
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair
Door Lock Cylinder: Service and Repair
Door Lock Cylinder
Removal and Installation
NOTE: When any new lock cylinder is installed, the driver door and ignition lock cylinders should
be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is
used, the new key code number is stamped on a metal tag attached to the key.
NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a
new lock cylinder using the appropriate lock repair package. The lock repair package includes a
detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. Remove the front door trim panel.
2. Position the watershield aside.
3. Release the front door push button rod from the door frame retainer.
4. Remove the exterior front door handle nut (rear).
- To install, tighten to 9 Nm (80 lb-in).
5. Remove the door lock cylinder.
- Disconnect the front door lock cylinder actuating rod.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key
Programming Switch State Control
Key: Testing and Inspection Key Programming Switch State Control
Key Programming Switch State Control
NOTE: The spare key programming switch is a programmable switch which provides the capability
to enable/disable the normal customer spare key programming procedure detailed in the Owner's
Literature. It must read ENABLE if more than 2 keys need to be programmed into the Instrument
Cluster (IC). For additional information, refer to Key Programming Using Two Programmed Keys
See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. This
programmable switch is provided as a convenience for rental company fleets or other fleet
purchasers who may not want the spare key programming procedure available to the vehicle
driver.
NOTE: The spare key programming switch state can be viewed with the IC PID SPAREKEY.
NOTE: If the SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the IC
using Key Programming Using Two Programmed Keys See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key
Programming Using Two Programmed Keys. If the SPAREKEY PID reads DISABLED, the Key
Programming Using Two Programmed Keys procedure will not function. This switch is set to
ENABLE when the vehicle is built. This PID does not affect the Key Programming Using Diagnostic
Equipment, the Spare Key Programming - Unlimited Key Mode or the Spare Key Programming Using Diagnostic Equipment procedures.
1. Insert a programmed Passive Anti-Theft System (PATS) key into the ignition lock cylinder and
turn the key from the OFF position to the ON
position.
2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow
the on-screen instructions to ENTER
SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See:
Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Component Tests and General Diagnostics.
3. NOTE: The default setting of the key programming switch on delivery of all new vehicles is
ENABLED, when viewing the IC PID SPAREKEY.
From the scan tool menu select: "Customer Spare Key Programming Enable" (or "Customer Spare
Key Programming Disable"), and follow the on-screen instructions. "Customer Spare Key Programming Enable" - the spare key programming procedure is accessible.
- "Customer Spare Key Programming Disable" - the spare key programming procedure is not
accessible.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key
Programming Switch State Control > Page 7567
Key: Testing and Inspection Key Programming Using Diagnostic Equipment
Key Programming Using Diagnostic Equipment
NOTE: This procedure is used when a customer needs keys programmed into the system and
does not have 2 programmed ignition keys available. This procedure is also useful when a
programmed ignition key(s) is lost or the ignition lock cylinder is replaced, and it is desired to erase
key code(s) from the Passive Anti-Theft System (PATS) memory.
NOTE: This procedure erases all programmed ignition keys from the vehicle memory. The vehicle
will not start until a minimum of 2 keys are programmed into the Instrument Cluster (IC).
NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle will start.
NOTE: Two PATS encoded (contains a transponder) keys with the correct mechanical cut must be
available to carry out this procedure. One or both of them may be the customer's original keys.
NOTE: If additional keys are to be programmed, refer to Key Programming Using Two
Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing
and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If
the remaining keys are with the customer and are not available with the vehicle, instruct the
customer to refer to the Owner's Literature for instructions on programming the remaining keys. In
this case, the PID SPAREKEY must be enabled.
NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of
the transceiver does not erase the PATS key codes in the IC.
1. Turn the key from the OFF position to the ON position.
2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow
the on-screen instructions to ENTER
SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See:
Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Component Tests and General Diagnostics.
3. From the scan tool menu select: "Ignition Key Code Erase" and follow the on-screen instructions.
4. Turn the key to the OFF position and disconnect the scan tool.
5. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3
seconds.
6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder.
7. Insert the next PATS key into the ignition lock cylinder and turn the key to the ON position for 3
seconds.
8. The vehicle should now start with both PATS ignition keys.
9. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the
IC), refer to Key Programming Using Two
Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing
and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for
each additional key that needs to be programmed.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key
Programming Switch State Control > Page 7568
Key: Testing and Inspection Key Programming Using Two Programmed Keys
Key Programming Using Two Programmed Keys
NOTE: This procedure only works if 2 or more programmed ignition keys are available. If 2
programmed keys are not available, refer to Key Programming Using Diagnostic Equipment See:
Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Programming and Relearning/Key Programming Using Diagnostic Equipment.
NOTE: The Instrument Cluster (IC) PID SPAREKEY must be enabled for this procedure to operate.
If this IC PID is not enabled, refer to Key Programming Switch State Control See: Accessories and
Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and
Relearning/Key Programming Switch State Control, then select SPAREKEY programming switch;
ENABLED. The IC PID SPAREKEY is set to ENABLE when the vehicle is built.
NOTE: If the programming procedure is successful, the new key(s) will start the vehicle and the
anti-theft indicator will prove-out for approximately 3 seconds. If the programming procedure is not
successful and the new key(s) does not start the engine, leave the key in the ON position for at
least 3 seconds, then turn the key off. Repeat the key programming procedure from Step 1. If the
failure repeats, refer to Anti-Theft See: Accessories and Optional Equipment/Antitheft and Alarm
Systems/Testing and Inspection in the Diagnosis and Testing to review the DTCs and carry out the
appropriate pinpoint tests.
NOTE: A maximum of 8 Passive Anti-Theft System (PATS) keys can be programmed into the IC
during this programming procedure, but only if the IC PID SPAREKEY is ENABLED.
NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle will start.
NOTE: If the vehicle is in unlimited key mode, this spare key programming procedure still functions.
Any 2 keys that can start the vehicle can be used to program an additional unlimited key.
NOTE: If additional keys are to be programmed, and the remaining keys are with the customer, or
are not available, instruct the customer to refer to the Owner's Literature for instructions on
programming the remaining keys. In this case, the IC PID SPAREKEY must be enabled.
NOTE: If the steps are not carried out as outlined, the programming procedure will end.
NOTE: Ignition keys must have a correct mechanical key cut for the vehicle and must be PATS
encoded keys (contain a transponder).
NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of
the transceiver does not erase the PATS key codes in the IC.
NOTE: When in the unlimited key mode, the N_KEYCODE PID will always read 2 (after the first 2
keys have been programmed), no matter how many keys are programmed to the vehicle.
1. Insert the first programmed key into the ignition lock cylinder and turn the key from the OFF
position to the ON position (maintain the key in the
ON position for a minimum of 3 seconds and less than 10 seconds).
2. Turn the key to the OFF position and remove the first key from the ignition lock cylinder.
3. Within 5 seconds of turning the key to the OFF position, insert the second programmed key into
the ignition lock cylinder and turn the key from
the OFF position to the ON position (maintain the key in the ON position for a minimum of 3
seconds and less than 10 seconds).
4. Turn the key to the OFF position and remove the key from the ignition lock cylinder.
5. Within 10 seconds of turning the key to the OFF position, insert the unprogrammed key (the new
key) into the ignition lock cylinder and turn the
key from the OFF position to the ON position (maintain the key in the ON position for a minimum of
3 seconds and less than 10 seconds).
6. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the
IC), repeat Steps 1-5 for each additional key that
needs to be programmed.
7. Start the vehicle with the new key(s).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key
Programming Switch State Control > Page 7569
Key: Testing and Inspection Spare Key Programming - Unlimited Key Mode
Spare Key Programming - Unlimited Key Mode
Enabling Unlimited Key Mode
NOTE: Unlimited key mode is intended for use by those customers who need more than 8 keys for
their vehicle.
NOTE: Before programming, the new key(s) must have the correct mechanical cut for the ignition
lock cylinder(s).
NOTE: The unlimited key mode is set up by creating a special, unique unlimited transponder
security key code and programming this key code into all of the vehicle keys so they contain the
same key code.
NOTE: When in the unlimited key mode, the N_KEYCODE PID always reads 2, no matter how
many keys are programmed to the vehicle (after the first 2 keys have been programmed).
1. The customer must choose an 8-digit number (except for 00000000 or 00000001) to be
programmed into all of their vehicles keys (or, to all of the
keys they want programmed to one vehicle). All customer vehicles keys (or all keys for one vehicle)
need to use the same number. Valid digits are 0-9 and the letters A-F.
2. NOTE: If the Instrument Cluster (IC) UNL_KEY_ID PID is not available, unlimited key mode is
turned on, and must be turned off before
viewing the stored code. At this time, unlimited keys may be programmed to the vehicle(s). To
view/change the stored code, follow the procedure for disabling the unlimited key mode below.
Monitor the IC UNL_KEY_ID PID and compare its value against the code chosen in Step 1. It
should not be the same key code.
3. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the
on-screen instructions to ENTER SECURITY
ACCESS. This procedure takes approximately 10 minutes to carry out, during which time the
ignition key must be in the
ON position and the scan tool must be connected to the vehicle. For additional information, refer to
Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm
Systems/Testing and Inspection/Component Tests and General Diagnostics.
4. Once in security access, select: "program unlimited key code" and follow the on-screen
instructions. Enter the 8-digit code chosen by the customer
in Step 1 of this procedure and follow the on-screen instructions.
5. Select: "unlimited key mode ON" and follow the on-screen instructions.
6. Select: "Ignition Key Code Erase" and follow the on-screen instructions.
7. Disconnect the scan tool and turn the ignition key to the OFF position (the key does not need to
be removed at this time).
8. Turn the first Passive Anti-Theft System (PATS) key in the ignition lock cylinder to the ON
position for 3 seconds.
9. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder.
10. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position
for 3 seconds.
11. The vehicle should now start with both PATS keys.
12. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed
Keys See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key
Programming Using Two Programmed Keys for each additional key that needs to be programmed.
Disabling Unlimited Key Mode
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key
Programming Switch State Control > Page 7570
NOTE: By disabling the unlimited key mode, the previous access code no longer operates the
vehicle.
1. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the
on-screen instructions to ENTER SECURITY
ACCESS. This procedure takes approximately 10 minutes to carry out, during which time the
ignition key must be in the ON position and the scan tool must be connected to the vehicle. For
additional information, refer to Anti-Theft Security Access See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General
Diagnostics.
2. Select: "unlimited key mode OFF" and follow the on-screen instructions.
3. Select: "Ignition Key Code Erase" and follow the on-screen instructions.
4. Disconnect the scan tool and turn the ignition switch to the OFF position (the key does not need
to be removed at this time).
5. Turn the first PATS key in the ignition lock cylinder to the ON position for 3 seconds.
6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder.
7. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for
3 seconds.
8. NOTE: With the unlimited key mode turned off, a maximum of 8 keys can be programmed into
the Instrument Cluster (IC) using the Key
Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft
and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using
Two Programmed Keys procedure. The IC SPAREKEY PID must be enabled.
If it is desired to program additional key(s), refer to Key Programming Using Two Programmed
Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each
additional key (up to 8 keys, total) that needs to be programmed. The IC SPAREKEY PID must be
enabled.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key
Programming Switch State Control > Page 7571
Key: Testing and Inspection
Key Programming Switch State Control
Key Programming Switch State Control
NOTE: The spare key programming switch is a programmable switch which provides the capability
to enable/disable the normal customer spare key programming procedure detailed in the Owner's
Literature. It must read ENABLE if more than 2 keys need to be programmed into the Instrument
Cluster (IC). For additional information, refer to Key Programming Using Two Programmed Keys
See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. This
programmable switch is provided as a convenience for rental company fleets or other fleet
purchasers who may not want the spare key programming procedure available to the vehicle
driver.
NOTE: The spare key programming switch state can be viewed with the IC PID SPAREKEY.
NOTE: If the SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the IC
using Key Programming Using Two Programmed Keys See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key
Programming Using Two Programmed Keys. If the SPAREKEY PID reads DISABLED, the Key
Programming Using Two Programmed Keys procedure will not function. This switch is set to
ENABLE when the vehicle is built. This PID does not affect the Key Programming Using Diagnostic
Equipment, the Spare Key Programming - Unlimited Key Mode or the Spare Key Programming Using Diagnostic Equipment procedures.
1. Insert a programmed Passive Anti-Theft System (PATS) key into the ignition lock cylinder and
turn the key from the OFF position to the ON
position.
2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow
the on-screen instructions to ENTER
SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See:
Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Component Tests and General Diagnostics.
3. NOTE: The default setting of the key programming switch on delivery of all new vehicles is
ENABLED, when viewing the IC PID SPAREKEY.
From the scan tool menu select: "Customer Spare Key Programming Enable" (or "Customer Spare
Key Programming Disable"), and follow the on-screen instructions. "Customer Spare Key Programming Enable" - the spare key programming procedure is accessible.
- "Customer Spare Key Programming Disable" - the spare key programming procedure is not
accessible.
Key Programming Using Diagnostic Equipment
Key Programming Using Diagnostic Equipment
NOTE: This procedure is used when a customer needs keys programmed into the system and
does not have 2 programmed ignition keys available. This procedure is also useful when a
programmed ignition key(s) is lost or the ignition lock cylinder is replaced, and it is desired to erase
key code(s) from the Passive Anti-Theft System (PATS) memory.
NOTE: This procedure erases all programmed ignition keys from the vehicle memory. The vehicle
will not start until a minimum of 2 keys are
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key
Programming Switch State Control > Page 7572
programmed into the Instrument Cluster (IC).
NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle will start.
NOTE: Two PATS encoded (contains a transponder) keys with the correct mechanical cut must be
available to carry out this procedure. One or both of them may be the customer's original keys.
NOTE: If additional keys are to be programmed, refer to Key Programming Using Two
Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing
and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If
the remaining keys are with the customer and are not available with the vehicle, instruct the
customer to refer to the Owner's Literature for instructions on programming the remaining keys. In
this case, the PID SPAREKEY must be enabled.
NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of
the transceiver does not erase the PATS key codes in the IC.
1. Turn the key from the OFF position to the ON position.
2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow
the on-screen instructions to ENTER
SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See:
Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Component Tests and General Diagnostics.
3. From the scan tool menu select: "Ignition Key Code Erase" and follow the on-screen instructions.
4. Turn the key to the OFF position and disconnect the scan tool.
5. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3
seconds.
6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder.
7. Insert the next PATS key into the ignition lock cylinder and turn the key to the ON position for 3
seconds.
8. The vehicle should now start with both PATS ignition keys.
9. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the
IC), refer to Key Programming Using Two
Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing
and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for
each additional key that needs to be programmed.
Key Programming Using Two Programmed Keys
Key Programming Using Two Programmed Keys
NOTE: This procedure only works if 2 or more programmed ignition keys are available. If 2
programmed keys are not available, refer to Key Programming Using Diagnostic Equipment See:
Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Programming and Relearning/Key Programming Using Diagnostic Equipment.
NOTE: The Instrument Cluster (IC) PID SPAREKEY must be enabled for this procedure to operate.
If this IC PID is not enabled, refer to Key Programming Switch State Control See: Accessories and
Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and
Relearning/Key Programming Switch State Control, then select SPAREKEY programming switch;
ENABLED. The IC PID SPAREKEY is set to ENABLE when the vehicle is built.
NOTE: If the programming procedure is successful, the new key(s) will start the vehicle and the
anti-theft indicator will prove-out for approximately 3 seconds. If the programming procedure is not
successful and the new key(s) does not start the engine, leave the key in the ON position for at
least 3 seconds, then turn the key off. Repeat the key programming procedure from Step 1. If the
failure repeats, refer to Anti-Theft See: Accessories and Optional Equipment/Antitheft and Alarm
Systems/Testing and Inspection in the Diagnosis and Testing to review the DTCs and carry out the
appropriate pinpoint tests.
NOTE: A maximum of 8 Passive Anti-Theft System (PATS) keys can be programmed into the IC
during this programming procedure, but only if the IC PID SPAREKEY is ENABLED.
NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle will start.
NOTE: If the vehicle is in unlimited key mode, this spare key programming procedure still functions.
Any 2 keys that can start the vehicle can be used to program an additional unlimited key.
NOTE: If additional keys are to be programmed, and the remaining keys are with the customer, or
are not available, instruct the customer to refer to the
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key
Programming Switch State Control > Page 7573
Owner's Literature for instructions on programming the remaining keys. In this case, the IC PID
SPAREKEY must be enabled.
NOTE: If the steps are not carried out as outlined, the programming procedure will end.
NOTE: Ignition keys must have a correct mechanical key cut for the vehicle and must be PATS
encoded keys (contain a transponder).
NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of
the transceiver does not erase the PATS key codes in the IC.
NOTE: When in the unlimited key mode, the N_KEYCODE PID will always read 2 (after the first 2
keys have been programmed), no matter how many keys are programmed to the vehicle.
1. Insert the first programmed key into the ignition lock cylinder and turn the key from the OFF
position to the ON position (maintain the key in the
ON position for a minimum of 3 seconds and less than 10 seconds).
2. Turn the key to the OFF position and remove the first key from the ignition lock cylinder.
3. Within 5 seconds of turning the key to the OFF position, insert the second programmed key into
the ignition lock cylinder and turn the key from
the OFF position to the ON position (maintain the key in the ON position for a minimum of 3
seconds and less than 10 seconds).
4. Turn the key to the OFF position and remove the key from the ignition lock cylinder.
5. Within 10 seconds of turning the key to the OFF position, insert the unprogrammed key (the new
key) into the ignition lock cylinder and turn the
key from the OFF position to the ON position (maintain the key in the ON position for a minimum of
3 seconds and less than 10 seconds).
6. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the
IC), repeat Steps 1-5 for each additional key that
needs to be programmed.
7. Start the vehicle with the new key(s).
Spare Key Programming - Unlimited Key Mode
Spare Key Programming - Unlimited Key Mode
Enabling Unlimited Key Mode
NOTE: Unlimited key mode is intended for use by those customers who need more than 8 keys for
their vehicle.
NOTE: Before programming, the new key(s) must have the correct mechanical cut for the ignition
lock cylinder(s).
NOTE: The unlimited key mode is set up by creating a special, unique unlimited transponder
security key code and programming this key code into all of the vehicle keys so they contain the
same key code.
NOTE: When in the unlimited key mode, the N_KEYCODE PID always reads 2, no matter how
many keys are programmed to the vehicle (after the first 2 keys have been programmed).
1. The customer must choose an 8-digit number (except for 00000000 or 00000001) to be
programmed into all of their vehicles keys (or, to all of the
keys they want programmed to one vehicle). All customer vehicles keys (or all keys for one vehicle)
need to use the same number. Valid digits are 0-9 and the letters A-F.
2. NOTE: If the Instrument Cluster (IC) UNL_KEY_ID PID is not available, unlimited key mode is
turned on, and must be turned off before
viewing the stored code. At this time, unlimited keys may be programmed to the vehicle(s). To
view/change the stored code, follow the procedure for disabling the unlimited key mode below.
Monitor the IC UNL_KEY_ID PID and compare its value against the code chosen in Step 1. It
should not be the same key code.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key
Programming Switch State Control > Page 7574
3. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the
on-screen instructions to ENTER SECURITY
ACCESS. This procedure takes approximately 10 minutes to carry out, during which time the
ignition key must be in the
ON position and the scan tool must be connected to the vehicle. For additional information, refer to
Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm
Systems/Testing and Inspection/Component Tests and General Diagnostics.
4. Once in security access, select: "program unlimited key code" and follow the on-screen
instructions. Enter the 8-digit code chosen by the customer
in Step 1 of this procedure and follow the on-screen instructions.
5. Select: "unlimited key mode ON" and follow the on-screen instructions.
6. Select: "Ignition Key Code Erase" and follow the on-screen instructions.
7. Disconnect the scan tool and turn the ignition key to the OFF position (the key does not need to
be removed at this time).
8. Turn the first Passive Anti-Theft System (PATS) key in the ignition lock cylinder to the ON
position for 3 seconds.
9. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder.
10. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position
for 3 seconds.
11. The vehicle should now start with both PATS keys.
12. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed
Keys See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key
Programming Using Two Programmed Keys for each additional key that needs to be programmed.
Disabling Unlimited Key Mode
NOTE: By disabling the unlimited key mode, the previous access code no longer operates the
vehicle.
1. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the
on-screen instructions to ENTER SECURITY
ACCESS. This procedure takes approximately 10 minutes to carry out, during which time the
ignition key must be in the ON position and the scan tool must be connected to the vehicle. For
additional information, refer to Anti-Theft Security Access See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General
Diagnostics.
2. Select: "unlimited key mode OFF" and follow the on-screen instructions.
3. Select: "Ignition Key Code Erase" and follow the on-screen instructions.
4. Disconnect the scan tool and turn the ignition switch to the OFF position (the key does not need
to be removed at this time).
5. Turn the first PATS key in the ignition lock cylinder to the ON position for 3 seconds.
6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder.
7. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for
3 seconds.
8. NOTE: With the unlimited key mode turned off, a maximum of 8 keys can be programmed into
the Instrument Cluster (IC) using the Key
Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft
and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using
Two Programmed Keys procedure. The IC SPAREKEY PID must be enabled.
If it is desired to program additional key(s), refer to Key Programming Using Two Programmed
Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each
additional key (up to 8 keys, total) that needs to be programmed. The IC SPAREKEY PID must be
enabled.
Spare Key Programming - Using Diagnostic Equipment
Spare Key Programming - Using Diagnostic Equipment
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key
Programming Switch State Control > Page 7575
NOTE: This procedure is used when a customer needs to have an additional key programmed into
the vehicle without erasing stored key codes, but does not have 2 programmed keys available. This
procedure is also useful when attempting to determine if an ignition key is damaged, as a new key
can be installed without erasing keys or without having 2 programmed keys available.
NOTE: Before programming, the new key must have the correct mechanical cut for the ignition lock
cylinder.
NOTE: If 8 keys are already programmed, this procedure does not allow any more ignition keys to
be programmed. The number of keys that are programmed into the Passive Anti-Theft System
(PATS) can be determined by viewing the Instrument Cluster (IC) PID N_KEYCODE.
NOTE: When in the unlimited key mode, the N_KEYCODE PID will always read 2 (after the first 2
keys have been programmed), no matter how many keys are programmed to the vehicle.
1. Turn the unprogrammed PATS key from the OFF position to the ON position.
2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow
the on-screen instructions to ENTER
SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See:
Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Component Tests and General Diagnostics.
3. NOTE: Make sure the selection made is "PROGRAM" (Program additional ignition key). If the
"ERASE" (Ignition Key Code Erase) selection is
made, all of the keys will be erased from the system.
From the scan tool menu select: "Program additional ignition key" and follow the on-screen
instructions.
4. Turn the key to the OFF position and disconnect the scan tool.
5. Start the vehicle with the new PATS key. The vehicle will now start with the new PATS key and
also with the original PATS keys.
Passive Anti-Theft System (PATS) Parameter Reset
Passive Anti-Theft System (PATS) Parameter Reset
NOTE: When using the Integrated Diagnostic System (IDS), the Instrument Cluster (IC) and the
PCM parameters are reset at the same time.
1. Turn the key from the OFF position to the ON position.
2. From the scan tool, follow the on-screen instructions to ENTER SECURITY ACCESS. For
additional information, refer to Anti-Theft Security
Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Component Tests and General Diagnostics .
3. From the scan tool, select: Parameter Reset and follow the on-screen instructions.
4. NOTE: If the IC was replaced, follow Steps 4-9. If the IC and the PCM were replaced, follow
Steps 4-9. If only the PCM was replaced, go to Step
9.
From the scan tool, select: Ignition Key Code Erase and follow the on-screen instructions.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key
Programming Switch State Control > Page 7576
5. Turn the key to the OFF position and disconnect the scan tool.
6. Turn the key to the ON position for a minimum of 3 seconds.
7. Turn the key to the OFF position and remove the key.
8. Insert the second key into the ignition lock cylinder and turn the key to the ON position for a
minimum of 3 seconds.
9. Both keys will now start the vehicle.
10. If more keys are required to be programmed, refer to Key Programming Using Two
Programmed Keys See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key
Programming Using Two Programmed Keys.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Locations > Page 7581
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Locations > Page 7582
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Locations > Page 7583
Keyless Entry Key-Pad: Service and Repair
Keyless Entry Keypad
Removal and Installation
1. Position the front window glass to the full down position.
2. Position the door glass top run aside to access the door pillar trim panel screws.
3. Remove the 3 door pillar trim panel screws and the door pillar trim panel.
4. Disconnect the electrical connector and remove the keyless entry keypad from the door pillar
trim panel.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming
Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry (RKE) Transmitter
Programming
Remote Keyless Entry (RKE) Transmitter Programming
NOTE: All Remote Keyless Entry (RKE) transmitters must be programmed at the same time.
NOTE: 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 the 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 Locks, Latches and Entry Systems See: Power Locks/Testing and Inspection. Make sure
that no more than the maximum number of 6 RKE transmitters are attempted to be programmed.
5. Exiting the programming mode is accomplished if one of the following occurs:
- The key transitions to the OFF position.
- Twenty seconds have passed since entering programming mode or since the last RKE transmitter
was programmed.
- The maximum number of 6 RKE transmitters have been programmed.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 7588
Keyless Entry Transmitter: Testing and Inspection Autolock and Auto-Unlock Programming
Autolock and Auto-Unlock 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 7589
Within 5 seconds of Step 3, release the 3/4 button on the keyless entry keypad.
Auto-Unlock Programming Using the Ignition Lock Cylinder
1. Close all doors and windows.
2. Confirm that the ignition key is OFF.
3. NOTE: Steps 5 through 9 must be carried out within 30 seconds.
Turn the ignition key from OFF to RUN.
4. Press the door lock control switch UNLOCK button 3 times.
5. Turn the ignition key from RUN to OFF.
6. Press the door lock control switch UNLOCK button 3 times.
7. Turn the ignition key from OFF to RUN.
8. Verify the horn chirps. This indicates the enable/disable mode and now is ready to accept
program changes.
9. Press the door lock control switch LOCK button then the UNLOCK button 1 time to command the
module to toggle the auto-unlock feature.
10. Verify that the horn chirps. There should be 1 chirp indicating that auto-unlock feature has been
disabled. If 1 chirp is heard, followed by a longer
sound of the horn, the auto-unlock feature has just been enabled.
11. Turn the key to the OFF position or wait 2 minutes to exit the enable/disable mode.
12. Verify that the horn chirps once to indicate that a feature has been changed and that
auto-unlock has been toggled.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 7590
Keyless Entry Transmitter: Testing and Inspection 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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 7591
Keyless Entry Transmitter: Testing and Inspection Remote Memory Deactivation
Remote Memory Deactivation
1. Press the set button on the lower center of the instrument panel.
2. Within 5 seconds press one control on the Remote Keyless Entry (RKE) transmitter and then the
set button on the lower center of the instrument
panel to associate the RKE transmitter to the driver 1 or the driver 2 position.
3. If a second memory setting is desired to be deactivated, repeat the procedure with the second
RKE transmitter.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 7592
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Door Lock Actuator, Right Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Door Lock Actuator, Right Front > Page 7598
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Door Lock Actuator, Right Front > Page 7599
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Door Lock Actuator, Right Front > Page 7600
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Door Lock Actuator, Left Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Door Lock Actuator, Left Front > Page 7603
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Door Lock Actuator, Left Front > Page 7604
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Door Lock Actuator, Left Front > Page 7605
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Service and Repair > Front Door Lock Actuator
Power Door Lock Actuator: Service and Repair Front Door Lock Actuator
Front Door Lock Actuator
Removal and Installation
1. Remove the front door latch. For additional information, refer to Front Door Latch See: Doors,
Hood and Trunk/Doors/Front Door/Front Door
Latch/Service and Repair/Removal and Replacement/Front Door Latch.
2. Disconnect the front door ajar switch and the front door lock actuator electrical connectors.
3. Release the locking tab and remove the front door lock actuator.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Service and Repair > Front Door Lock Actuator > Page 7608
Power Door Lock Actuator: Service and Repair Rear Door Lock Actuator
Rear Door Lock Actuator
Removal and Installation
1. Remove the rear door latch. For additional information, refer to Rear Door Latch See: Doors,
Hood and Trunk/Doors/Rear Door/Rear Door
Latch/Service and Repair/Removal and Replacement/Rear Door Latch.
2. Release the locking tab and remove the rear door lock actuator.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Locations > Door Lock Switch, Passenger Side
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Locations > Door Lock Switch, Passenger Side > Page 7613
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Door Lock Switch, Driver Side
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Door Lock Switch, Driver Side > Page 7616
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Page 7617
Power Door Lock Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Page 7618
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Page 7619
Power Door Lock Switch: Service and Repair
Door Lock Control Switch
Removal and Installation
NOTE: The LH side is shown, the RH side is similar.
1. Remove the interior door handle cover.
2. Remove the front door switch bezel.
- Release the 4 retaining tabs.
3. Disconnect the door lock control switch and window control switch electrical connectors.
4. Remove the door lock control switch.
- Release the 4 retaining tabs.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock > System Information > Service and Repair
Trunk / Liftgate Lock: Service and Repair
Liftgate Handle, Lock and Latch - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 7628
Memory Positioning Module: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 7629
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 7630
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 7631
Memory Positioning Module: Service and Repair
Driver Seat Module (DSM)
Removal and Installation
NOTICE: 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 Driver Seat Module
(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: When a new DSM is installed, it is necessary to download the module configuration
information from the scan tool into the new DSM.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 7632
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations > Page 7636
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair
Power Mirror Motor: Service and Repair
Exterior Mirror Motor
Removal and Installation
NOTE: RH shown, LH similar.
1. Remove the exterior mirror glass. For additional information, refer to Exterior Mirror Glass See:
Service and Repair/Exterior Mirror Glass.
2. Remove the exterior mirror motor screws.
3. Disconnect the exterior mirror motor electrical connectors.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
7643
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
7644
Power Mirror Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
7645
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
7646
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
7647
Power Mirror Switch: Service and Repair
Exterior Mirror Control Switch
Removal and Installation
1. Remove the front door trim panel.
2. Depress the 2 retaining tabs and remove the exterior mirror control switch from the front door
trim panel.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 7652
Memory Positioning Module: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 7653
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 7654
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 7655
Memory Positioning Module: Service and Repair
Driver Seat Module (DSM)
Removal and Installation
NOTICE: 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 Driver Seat Module
(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: When a new DSM is installed, it is necessary to download the module configuration
information from the scan tool into the new DSM.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 7656
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 7661
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 7662
Power Seat Relay: Locations Third Row Folding Seat Relay, Right
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 7663
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component
Information > Diagrams > Third Row Folding Seat Relay, Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 7666
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 7669
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 7670
Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 7671
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Locations > Page 7675
Auxiliary Step / Running Board Module: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Locations > Page 7676
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Locations > Page 7677
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Service and Repair
Seat Heater Control Module: Service and Repair
Seat - Exploded View, Front
Front Seat Backrest
NOTE: Driver backrest shown, passenger backrest similar.
Driver Seat Cushion
NOTE: Power seat track shown, manual seat track similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Service and Repair > Page 7681
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Service and Repair > Page 7682
Passenger Seat Cushion
NOTE: Manual seat track shown, power seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Service and Repair > Page 7683
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Service and Repair > Page 7684
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations
Sunroof / Moonroof Module: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations > Page 7688
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations > Page 7689
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component
Information > Locations > Page 7693
Trailer Towing Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component
Information > Locations > Page 7694
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Service and Repair > Roof Opening Panel - Exploded View
Sunroof / Moonroof Motor: Service and Repair Roof Opening Panel - Exploded View
Roof Opening Panel - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7701
Sunroof / Moonroof Motor: Service and Repair Roof Opening Panel Motor
Roof Opening Panel Motor
Removal and Installation
NOTICE: 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. For additional information,
refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and
Relearning.
1. 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.
NOTE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Roof Opening Panel - Exploded View
Sunroof / Moonroof Track: Service and Repair Roof Opening Panel - Exploded View
Roof Opening Panel - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7709
Sunroof / Moonroof Track: Service and Repair Trough Assembly
Trough Assembly
Removal and Installation
1. Remove the roof opening panel glass. For additional information, refer to Roof Opening Panel
Glass See: Sunroof / Moonroof Panel/Service and
Repair/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.
- Align 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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Windguard > Component Information > Service and Repair > Roof Opening Panel - Exploded View
Sunroof / Moonroof Windguard: Service and Repair Roof Opening Panel - Exploded View
Roof Opening Panel - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Windguard > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7714
Sunroof / Moonroof Windguard: Service and Repair Air Deflector
Air Deflector
Removal and Installation
1. Move the 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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Roof Opening Panel - Exploded View
Sunroof / Moonroof Frame: Service and Repair Roof Opening Panel - Exploded View
Roof Opening Panel - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7719
Sunroof / Moonroof Frame: Service and Repair Roof Opening Panel Frame
Roof Opening Panel Frame
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. For additional information,
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.
NOTICE: 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.
- Align 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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Module > Component Information > Locations
Sunroof / Moonroof Module: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Module > Component Information > Locations > Page 7723
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Module > Component Information > Locations > Page 7724
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel - Exploded View
Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel - Exploded View
Roof Opening Panel - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7729
Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Glass
Roof Opening Panel Glass
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. For additional information,
refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and
Relearning.
1. Position 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.
- Align 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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7730
Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Shield
Roof Opening Panel Shield
Removal and Installation
1. Remove the roof opening panel glass. For additional information, refer to Roof Opening Panel
Glass See: 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7731
8. To install, reverse the removal procedure.
- Align 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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair
Head Rest: Service and Repair
Head Restraint Guide Sleeve
Removal
NOTE: Typical head restraint guide sleeve shown, others similar.
1. Push in on the 2 head restraint guide sleeve release buttons and remove the head restraint.
2. Obtain a flat-head screwdriver with a width of 4 mm (0.157 in) to 7 mm (0.275 in) and a
thickness of approximately 1 mm (0.039 in).
3. Align the screwdriver to the middle of the head restraint guide sleeve release button.
4. Position the screwdriver between the head restraint guide sleeve neck and backrest trim cover
and foam pad.
5. Position the screwdriver at a 45-degree angle.
6. NOTE: For retainer clarity, backrest trim cover and foam pad are removed.
Push the screwdriver in, bending the lock feature on the head restraint guide sleeve in.
7. While bending the lock feature in, push down on the screwdriver handle, prying the head
restraint guide sleeve up and disengaging it from the
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Page
7736
backrest frame crossmember.
8. Remove the head restraint guide sleeve.
- Discard the head restraint guide sleeve.
9. Repeat these steps for the head restraint guide sleeve on the opposite side.
Installation
NOTICE: Always install new head restraint guide sleeves. Difficult adjustment of the head restraint
may occur. Failure to follow these instructions may result in component failure.
NOTICE: The head restraint guide sleeves are not interchangeable. Failure to install the correct
head restraint guide sleeve at the correct position may result in component failure.
1. Make sure the holes in the backrest foam pad and backrest trim cover are aligned to the holes in
the backrest frame.
2. Install the head restraint guide sleeve with the large button and wide key on the LH side of the
seat.
3. Install the head restraint guide sleeve with the small button and thin key on the RH side of the
seat.
4. NOTICE: Do not attempt to seat the head restraint guide sleeve by hand. This may result in
excessive head restraint adjustment efforts
and permanent damage to the head restraint guide sleeve.
To allow the head restraint guide sleeve to slide freely through the backrest foam pad and backrest
trim cover, twist the head restraint guide sleeve while pushing it into the backrest frame hole as far
as it will go with hand pressure.
5. NOTICE: Striking effort should not result in any type of damage or distortion to the head restraint
guide sleeve. If a head restraint guide
sleeve is damaged, install a new one.
Using a non-marring mallet, strike the top of the head restraint guide sleeve with moderate force,
seating it in the backrest frame.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Page
7737
- Striking effort must be hard enough to snap the head restraint guide sleeve retainer in place in the
backrest frame.
6. Inspect the head restraint guide sleeve.
- Pull the head restraint guide sleeve out by hand, making sure it is locked in place. If the head
restraint guide sleeve can be removed by hand, repeat the installation procedure. If the head
restraint guide sleeve can be removed again after installing a second time, install a new head
restraint guide sleeve.
7. Repeat these steps for the head restraint guide sleeve on the opposite side.
8. After installation of 2 new head restraint guide sleeves, install the head restraint in the following
sequence.
1. Position the head restraint rods to the head restraint guide sleeve holes.
2. Push the head restraint down, guiding the rods into the head restraint guide sleeve holes.
3. Make sure the head restraint adjusts without excessive effort and locks in place.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 7742
Memory Positioning Module: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 7743
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 7744
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 7745
Memory Positioning Module: Service and Repair
Driver Seat Module (DSM)
Removal and Installation
NOTICE: 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 Driver Seat Module
(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: When a new DSM is installed, it is necessary to download the module configuration
information from the scan tool into the new DSM.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 7746
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations > Page 7750
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 7755
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 7756
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 7757
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 7758
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver
Seat Recliner Motor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver
Seat Recliner Motor > Page 7761
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver
Seat Recliner Motor > Page 7762
Power Seat Motor: Diagrams Power Seat Motor Assembly, Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver
Seat Recliner Motor > Page 7763
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver
Seat Recliner Motor > Page 7764
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver
Seat Recliner Motor > Page 7765
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat - Exploded View, Front
Power Seat Motor: Service and Repair Seat - Exploded View, Front
Seat - Exploded View, Front
Front Seat Backrest
NOTE: Driver backrest shown, passenger backrest similar.
Driver Seat Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat - Exploded View, Front > Page 7768
NOTE: Power seat track shown, manual seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat - Exploded View, Front > Page 7769
Passenger Seat Cushion
NOTE: Manual seat track shown, power seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat - Exploded View, Front > Page 7770
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat - Exploded View, Front > Page 7771
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat - Exploded View, Front > Page 7772
Power Seat Motor: Service and Repair Seat Recliner Motor
Seat Recliner Motor
Removal
1. Remove the front seat. For additional information, refer to Seat - Front See: Service and
Repair/Front Seats/Seat - Front.
2. Remove the front seat backrest. For additional information, refer to Seat Backrest - Front See:
Seat Back/Service and Repair/Removal and
Replacement/Front Seats/Seat Backrest - Front.
3. Remove the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners.
4. NOTICE: 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. NOTICE: Do not rotate the recliner shaft while not engaged to both recliners. Failure to do so will
cause the inboard and outboard
recliners to become out of synchronization.
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
All seats
1. NOTICE: Do not rotate the recliner shaft while not engaged to both recliners. Failure to do so will
cause the inboard and outboard
recliners to become out of synchronization.
Install the recliner motor in the following sequence.
1. Position the recliner shaft through the recliner motor and inboard recliner.
- Slight turning of the recliner shaft may be necessary.
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 engage 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. For additional information, refer to Seat Backrest - Front See: Seat
Back/Service and Repair/Removal and
Replacement/Front Seats/Seat Backrest - Front.
5. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this
time. For additional information, refer to Seat Front See: Service and Repair/Front Seats/Seat - Front.
Passenger seat
6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS. For additional information, refer to
General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing
and Inspection/Component Tests and General Diagnostics
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat - Exploded View, Front > Page 7773
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. For additional information, refer to Seat - Third Row
See: Service and Repair/Third Row
Seating/Seat - Third Row.
3. From under the RH seat, remove the 2 cushion pivot link assembly-to-cushion frame nuts.
- To install, tighten to 22 Nm (16 lb-ft).
4. Remove the 2 latch-to-floor mounting bracket nuts and separate the RH seat and power latch
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. If unable to position the seat to access the bolt, use a
suitable tool to remove the bolt.
- To install, tighten to 25 Nm (18 lb-ft).
6. Remove the 2 bolts and latch cover.
7. On the side with the motor being serviced, release the backrest trim cover lower J-clip, side
retainer and invert the cover up to access to 2
latch-to-backrest frame bolts.
8. 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
9. 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
10. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third
Row Folding Seat Relay, Left > Page 7778
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third
Row Folding Seat Relay, Left > Page 7779
Power Seat Relay: Locations Third Row Folding Seat Relay, Right
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third
Row Folding Seat Relay, Left > Page 7780
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Diagrams > Third
Row Folding Seat Relay, Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Diagrams > Third
Row Folding Seat Relay, Left > Page 7783
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and
Inspection > Third Row Folding Seat Relay, Left > Page 7786
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and
Inspection > Third Row Folding Seat Relay, Left > Page 7787
Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and
Inspection > Third Row Folding Seat Relay, Left > Page 7788
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third
Row Folding Seat Switch, Left
Power Seat Switch: Locations Third Row Folding Seat Switch, Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third
Row Folding Seat Switch, Left > Page 7793
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third
Row Folding Seat Switch, Left > Page 7794
Power Seat Switch: Locations Third Row Folding Seat Switch, Right
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third
Row Folding Seat Switch, Left > Page 7795
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third
Row Folding Seat Switch, Left > Page 7796
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third
Row Folding Seat Switch, Left > Page 7797
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power
Seat Switch, Left
Power Seat Switch: Diagrams Power Seat Switch, Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power
Seat Switch, Left > Page 7800
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power
Seat Switch, Left > Page 7801
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power
Seat Switch, Left > Page 7802
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power
Seat Switch, Left > Page 7803
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch, Left - 6-Way Power Seat
Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 6-Way Power Seat
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 7806
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 7807
Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 10-Way Power Seat
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 7808
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 7809
Power Seat Switch: Testing and Inspection Power Seat Switch, Right
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 7810
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat - Exploded View, Front
Power Seat Switch: Service and Repair Seat - Exploded View, Front
Seat - Exploded View, Front
Front Seat Backrest
NOTE: Driver backrest shown, passenger backrest similar.
Driver Seat Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat - Exploded View, Front > Page 7813
NOTE: Power seat track shown, manual seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat - Exploded View, Front > Page 7814
Passenger Seat Cushion
NOTE: Manual seat track shown, power seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat - Exploded View, Front > Page 7815
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat - Exploded View, Front > Page 7816
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat - Exploded View, Front > Page 7817
Power Seat Switch: Service and Repair Memory Set Switch
Memory Set Switch
Removal and Installation
1. Position the gear selector to NEUTRAL.
2. Remove the console trim ring.
3. Open the center console door, remove the 2 screws and pull up on the console finish panel to
release the retainers.
4. Disconnect the power point electrical connector and remove the console finish panel.
5. Pull out to release the retainers and separate the instrument panel center lower RH and LH
finish panels.
6. Pull out to release the retainers and separate the instrument panel center finish panel.
7. Disconnect the electrical connector, release the 4 tabs and remove the memory SET switch.
8. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat - Exploded View, Front > Page 7818
Power Seat Switch: Service and Repair Seat Control Switch
Seat Control Switch
Removal and Installation
All seats
1. Remove the front seat. For additional information, refer to Seat - Front See: Service and
Repair/Front Seats/Seat - Front.
2. Remove the cushion side shield in the following sequence.
1. Remove the clip and manual recline handle (if equipped).
2. Pull and remove the manual lumbar control knob (if equipped).
3. Remove the scrivet.
4. Remove the retention bracket screw and the retention bracket (if equipped).
5. Release the cushion side shield front clip.
6. From under the cushion side shield, release the 3 hook retainers.
7. Pull out on the cushion side shield at the back and release the pin-type retainer.
8. Separate the cushion trim cover elastic strap from the cushion side shield.
9. 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. For additional information, refer to Seat Front See: Service and Repair/Front Seats/Seat - Front.
Passenger seat
6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS. For additional information, refer to
General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing
and Inspection/Component Tests and General Diagnostics
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat - Exploded View, Front > Page 7819
Power Seat Switch: Service and Repair Seat Control Switch - Third Row
Seat Control Switch - Third Row
Removal and Installation
NOTE: The third row seat control switches are located in the LH quarter trim panel.
1. Pull out on the third row seat control switch bezel and separate from the LH quarter trim panel.
2. Disconnect the third row seat control switch(es), release the retainers and remove the third row
seat control switch(es).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement
Seat Back: Removal and Replacement
Seat - Exploded View, Front
Seat - Exploded View, Front
Front Seat Backrest
NOTE: Driver backrest shown, passenger backrest similar.
Driver Seat Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7824
NOTE: Power seat track shown, manual seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7825
Passenger Seat Cushion
NOTE: Manual seat track shown, power seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7826
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7827
1. For additional information, refer to the procedures.
Seat Backrest - Front
Seat Backrest - Front
Removal and Installation
NOTE: Driver shown, passenger similar.
All seats
1. Remove the front seat. For additional information, refer to Seat - Front See: Service and
Repair/Front Seats/Seat - Front.
2. Remove the cushion side shield in the following sequence.
1. Remove the clip and manual recline handle (if equipped).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7828
2. Pull and remove the manual lumbar control knob (if equipped).
- Make sure the lumbar is completely relaxed before removing the handle.
3. Remove the scrivet.
4. Remove the retention bracket screw and the retention bracket (if equipped).
5. Release the cushion side shield front clip.
6. From under the cushion side shield, release the 3 hook retainers.
7. Pull out on the cushion side shield at the back and release the pin-type retainer.
8. Separate the cushion trim cover elastic strap from the cushion side shield.
- With manual seat track, remove the cushion side shield.
9. With power seat track, 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7829
Passenger seat with heat
12. Disconnect the backrest heated seat mat electrical connector and route out the wire harness.
- Release any wire harness retainers.
All seats
13. Release the pin-type retainers, disconnect and route out the side air bag module electrical
connector and wire harness.
14. NOTE: Driver 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. For additional information, refer to Seat Front See: Service and Repair/Front Seats/Seat - Front.
Passenger seat
18. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS. For additional information, refer to
General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing
and Inspection/Component Tests and General Diagnostics
Seat - Exploded View, Second Row
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7830
Seat - Exploded View, Second Row
60 Percent E-Z Entry Backrest
60 Percent, E-Z Entry Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7831
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7832
40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7833
40 Percent, E-Z Entry Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7834
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7835
Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7836
Bucket, Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7837
Explorer/Mountaineer, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7838
Explorer Sport Trac, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7839
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7840
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7841
Second Row, 40 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7842
1. For additional information, refer to the procedures.
Seat Backrest - Second Row, 40 Percent E-Z Entry
Seat Backrest - Second Row, 40 Percent E-Z Entry
Removal
1. Remove the second row, 40 percent E-Z entry seat from the vehicle. For additional information,
refer to Seat - Second Row, 60/40, E-Z Entry
See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry.
2. NOTICE: 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7843
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.
NOTE: If the inboard recliner is not positioned to the recliner stop (or any upright position) when the
outboard recliner is positioned to the recliner stop and the release strap is let go of, the recliners
will not lock in place.
Pull the release strap at the outboard recliner and position the outboard recliner pin to contact the
recliner stop. Let go of the release strap and the inboard and outboard recliners will lock in place. Each recliner pin must contact the recliner outer plate (stop).
5. Position the backrest assembly to the inboard and outboard recliners and hand-start the 2
inboard and 2 outboard recliner-to-backrest frame bolts.
6. NOTICE: 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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7844
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. For additional information,
refer to Seat - Second Row, 60/40, E-Z Entry See:
Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry.
14. Cycle the backrest down and then back to the upright position. Make sure the inboard and
outboard recliners simultaneously and securely
lock in the upright position.
Seat Backrest - Second Row, 60 Percent, E-Z Entry
Seat Backrest - Second Row, 60 Percent, E-Z Entry
Removal
1. Remove the second row, 60 percent E-Z entry seat from the vehicle. For additional information,
refer to Seat - Second Row, 60/40, E-Z Entry
See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry.
2. NOTICE: 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.
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7845
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.
NOTE: If the latch feet are not locked around the strikers on the mounting plate, the recliners will
not lock in position.
NOTE: 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).
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. NOTICE: 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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7846
3. Install the outboard recliner-to-backrest frame upper bolt.
- Tighten to 55 Nm (41 lb-ft).
4. Install the outboard recliner-to-backrest frame lower bolt.
- Tighten to 55 Nm (41 lb-ft).
5. Position the kneeling mechanism release handle and cable back through the backrest frame and
backrest trim cover openings.
- Attach the kneeling mechanism release cable to the backrest frame.
6. Roll the backrest trim cover down, attach the hook-and-loop strips and connect the backrest trim
cover lower J-clip.
7. Position the kneeling mechanism release handle to the backrest opening and push in, engaging
the clips.
8. Route the outboard recliner release strap before installing the outboard recliner outer cover.
9. Position the outboard recliner outer cover, recliner handle and install the 3 screws.
10. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
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. For additional information,
refer to Seat - Second Row, 60/40, E-Z Entry See:
Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry.
13. Cycle the backrest down and then back to the upright position. Make sure the inboard and
outboard recliners simultaneously and securely
lock in the upright position.
Seat Backrest - Second Row, 40 Percent, Bench
Seat Backrest - Second Row, 40 Percent, Bench
Removal
1. Release the seat backrest J-clip.
2. Remove all the staples holding the backrest trim cover to the backrest support panel.
3. Invert the seat backrest trim cover and foam pad to access the latch cover screws.
4. Remove the 4 screws and the 2 covers. Detach the seat backrest material attachment from both
of the latch covers.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7847
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. NOTICE: 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.
Seat Backrest - Second Row, 60 Percent, Bench
Seat Backrest - Second Row, 60 Percent, Bench
Removal
All vehicles
1. Remove the second row 60 percent seat of the 60/40 bench seat. For additional information,
refer to Seat - Second Row, Sport Trac or Seat Second Row, Explorer, 60/40 Bench See: Service and Repair/Second Row Seating/Seat - Second
Row, 60/40 Bench.
Sport Trac vehicles
2. Remove the safety belt guide cover in the following sequence.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7848
1. Pull out at the bottom and release the 2 safety belt guide cover retainers.
2. Tip the bottom of the safety belt guide cover up to release the top retainer and remove the safety
belt guide cover.
3. Remove the retainers and the upper latch cover.
All vehicles
4. Remove the safety belt anchor bolt.
5. Release the backrest trim cover lower J-clips.
6. Remove all the staples holding the backrest trim cover to the backrest support panel.
7. Position the backrest trim cover and foam pad to access the latch cover screws.
8. Remove the latch covers in the following sequence.
1. Remove the 4 latch cover screws.
2. Detach the backrest trim cover from the latch covers.
3. Remove the latch covers.
Explorer and Mountaineer vehicles
9. Remove the 2 backrest support panel lower screws and detach the latch release cable from the
backrest support panel.
Sport Trac vehicles
10. NOTICE: Use care when separating the backrest 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 and invert the backrest trim cover. Pull the backrest trim
cover up over the top of the backrest frame to expose the backrest support panel screws and the
upper latch bolts.
11. Remove the backrest support panel in the following sequence.
1. Remove the backrest support panel screws.
2. Slide the backrest support panel down and release it from the safety belt retractor cover.
3. Release the latch release cable from the backrest support panel.
4. Remove the backrest support panel.
12. Remove the screw and the inner latch cover.
13. Remove the 2 upper latch bolts.
14. Separate the latch release cable pin-type retainer from the backrest frame.
All vehicles
15. Remove the outboard upper pivot latch bolt.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7849
16. Remove the 2 inboard and 2 outboard latch-to-backrest frame bolts.
17. Remove the 60 percent backrest.
- For Explorer and Mountaineer, position the latch release cable out from between the backrest
frame and backrest support panel.
Installation
Sport Trac vehicles
1. Install the backrest frame to the inboard and outboard latches in the following sequence.
1. Position the backrest frame to the inboard and outboard latches and hand-start the 2 inboard
and 2 outboard latch-to-backrest frame bolts.
2. Hand-start the outboard upper pivot latch bolt.
3. Install the 2 inboard latch-to-backrest frame bolts.
- Tighten to 40 Nm (30 lb-ft).
4. Install the 2 outboard latch-to-backrest frame bolts.
- Tighten to 40 Nm (30 lb-ft).
5. Install the outboard upper pivot latch bolt.
- Tighten to 40 Nm (30 lb-ft).
2. Position the upper latch and install the bolts.
- Tighten to 25 Nm (18 lb-ft).
3. Position the inner latch cover and install the screw.
4. NOTE: The safety belt retractor has been removed for clarity.
Position the backrest support panel to the backrest frame and route the latch release cable.
- The latch release cable is to pass between the backrest frame and the backrest support at the 2
points shown.
5. NOTE: The cable is to move freely after assembly.
Install the backrest support panel screws to the backrest frame.
- Attach the latch release cable to the backrest support panel.
Explorer and Mountaineer vehicles
6. NOTE: The cable is to move freely after assembly.
Position the backrest to the inboard and outboard latches and route the cable between the backrest
frame and support panel.
- The cable is to pass between the backrest frame and the backrest support at the 2 points shown.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7850
7. Install the backrest frame to the inboard and outboard latches in the following sequence.
1. Position the backrest frame to the inboard and outboard latches and hand-start the 2 inboard
and 2 outboard latch-to-backrest frame bolts.
2. Hand-start the outboard upper pivot latch bolt.
3. Install the 2 inboard latch-to-backrest frame bolts.
- Tighten to 40 Nm (30 lb-ft).
4. Install the 2 outboard latch-to-backrest frame bolts.
- Tighten to 40 Nm (30 lb-ft).
5. Install the outboard upper pivot latch bolt.
- Tighten to 40 Nm (30 lb-ft).
8. NOTE: The cable is to move freely after assembly.
Install the backrest support panel screws to the backrest frame.
- Attach the latch release cable to the backrest support panel.
9. Route the latch release cable through the inboard latch holder.
All vehicles
10. Position the latch release cable in front of the spring.
11. Roll the backrest trim cover down.
- For Sport Trac, route the safety belt through the backrest trim cover.
- Attach the backrest trim cover to backrest foam pad hook-and-loop strips.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7851
12. Attach the backrest trim cover to both of the latch covers. Position the 2 latch covers and install
the 4 screws.
13. Position the trim cover and install staples in the backrest support panel.
14. Attach the backrest trim cover J-clip.
15. Position the safety belt anchor and install the bolt.
- To install, tighten to 121 Nm (89 lb-ft).
Sport Trac vehicles
16. Position the upper latch cover and install the retainers.
17. Install the safety belt guide cover.
All vehicles
18. Install the second row 60 percent seat of the 60/40 bench seat. For additional information, refer
to Seat - Second Row, Sport Trac or Seat Second Row, Explorer, 60/40 Bench See: Service and Repair/Second Row Seating/Seat - Second
Row, 60/40 Bench.
Seat Backrest - Second Row, Bucket
Seat Backrest - Second Row, Bucket
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 Recliner - Second Row, 40 Percent E-Z Entry
Seat Recliner - Second Row, 40 Percent E-Z Entry
Removal and Installation
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.
NOTICE: The recliner bolts must be tightened in sequence or recliner latches that do not lock in
place or binding may occur.
Inboard and/or outboard recliners
1. Remove the second row, 40 percent E-Z entry seat from the vehicle. For additional information,
refer to Seat - Second Row, 60/40, E-Z Entry
See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry.
2. Remove the second row, 40 percent E-Z entry seat backrest. For additional information, refer to
Seat Backrest - Second Row, 40 Percent E-Z
Entry See: Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 40 Percent E-Z
Entry.
Outboard recliner
3. Remove 3 screws, recliner handle and outboard recliner outer cover.
4. Separate the outboard recliner.
- Remove the 2 outboard recliner-to-cushion frame bolts.
- NOTE: When pulling outboard recliner out, note keyed position of recliner release shaft as it may
pull out of inboard recliner.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Removal and Replacement > Page 7852
Pull out to release the outboard recliner from the recliner release shaft.
- Separate the outboard recliner.
5. Remove the outboard recliner inner cover.
6. 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.
Inboard recliner
7. Remove the 2 screws and inboard recliner outer cover.
8. Separate the inboard recliner.
- Remove the 2 inboard recliner-to-cushion frame bolts and the safety belt buckle.
- NOTE: When pulling the inboard recliner out, note keyed position of recliner release shaft as it
may pull out of outboard recliner.
Pull out to release the inboard recliner from the recliner release shaft.
- Separate the inboard recliner.
9. Remove the inboard recliner inner cover.
10. Remove the screw and separate the kneeling mechanism release cable pivot at the inboard
recliner.
- Remove the inboard recliner.
Installation
Inboard and/or outboard recliners
1. If necessary, position the recliner release shaft onto the recliner release pivot stub of the recliner
still attached to the seat.
Inboard recliner
2. Install the inboard recliner inner cover.
3. NOTE: The inboard recliner inner cover is removed for clarity.
Position the inboard recliner release pivot stub into the recliner shaft.
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Removal and Replacement > Page 7853
4. Install the 2 inboard recliner-to-cushion frame bolts.
- Tighten to 55 Nm (41 lb-ft).
5. Position the kneeling mechanism release cable pivot onto the inboard recliner and install the
screw.
- Make sure to put the recliner pin through the cable pivot.
Outboard recliner
6. NOTE: The cable ends are color coded/keyed to the levers.
Position each keyed cable end to the outboard recliner lever and rotate into position.
- Install the cable casing to the outboard recliner.
7. Install the outboard recliner inner cover.
8. NOTE: The outboard recliner inner cover is removed for clarity.
Position the outboard recliner release pivot stub into the recliner shaft.
9. Install the 2 outboard recliner-to-cushion frame bolts.
- Tighten to 55 Nm (41 lb-ft).
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Removal and Replacement > Page 7854
Inboard and/or outboard recliners
10. Install the second row, 40 percent E-Z entry seat backrest. For additional information, refer to
Seat Backrest - Second Row, 40 Percent E-Z Entry
See: Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 40 Percent E-Z Entry.
11. Install the second row, 40 percent E-Z entry seat into the vehicle. For additional information,
refer to Seat - Second Row, 60/40, E-Z Entry See:
Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry.
12. Cycle the backrest down and then back to the upright position. Make sure the inboard and
outboard recliners simultaneously and securely
lock in the upright position.
Seat Recliner - Inboard, Second Row, 60 Percent E-Z Entry
Seat Recliner - Inboard, Second Row, 60 Percent E-Z Entry
Removal
1. Remove the second row, 60 percent E-Z entry seat from the vehicle. For additional information,
refer to Seat - Second Row, 60/40, E-Z Entry
See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry.
2. Remove the second row, 60 percent E-Z entry seat backrest. For additional information, refer to
Seat Backrest - Second Row, 60 Percent, E-Z
Entry See: Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 60 Percent, E-Z
Entry.
3. Separate the kneeling mechanism release cable pivot at the inboard recliner.
4. Release the cushion trim cover at the inboard side of the cushion frame. Pull the cushion trim
cover back to expose 4 inboard recliner bolts.
5. Remove the inboard recliner.
- Remove the 2 inboard recliner-to-cushion frame bolts.
- Remove the inboard recliner-to-kneeling mechanism bolt.
- Remove the inboard recliner-to-latch feet assembly bolt.
- NOTE: When pulling inboard recliner out, note keyed position of recliner release shaft as it may
pull out of outboard recliner.
Pull out and remove the inboard recliner.
- Remove the inboard recliner inner cover.
Installation
1. If necessary, position the recliner release shaft onto the outboard recliner release pivot stub.
2. Install the inboard recliner inner cover.
3. NOTE: The inboard recliner inner cover has been removed for clarity.
Position the inboard recliner.
- Position the inboard recliner release pivot stub into the recliner release shaft.
- Align the inboard recliner to the cushion frame, latch feet assembly and kneeling mechanism.
4. Hand-start the 2 inboard recliner-to-cushion frame bolts, inboard recliner-to-latch feet assembly
bolt and inboard recliner-to-kneeling mechanism
bolt.
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Removal and Replacement > Page 7855
5. NOTICE: The recliner bolts must be tightened in sequence or recliner latches that do not lock in
place or binding may occur.
Install the inboard recliner bolts in the following sequence.
1. Install the inboard recliner-to-latch feet assembly bolt.
- Tighten to 55 Nm (41 lb-ft).
2. Install the inboard recliner-to-kneeling mechanism bolt.
- Tighten to 55 Nm (41 lb-ft).
3. Install the inboard recliner-to-cushion frame rear bolt.
- Tighten to 55 Nm (41 lb-ft).
4. Install the inboard recliner-to-cushion frame front bolt.
- Tighten to 55 Nm (41 lb-ft).
6. Position the kneeling mechanism release cable pivot at the inboard recliner.
- Make sure the inboard recliner pin is through the cable pivot.
7. Attach the cushion trim cover retainers at the inboard side of the cushion frame.
8. Install the second row, 60 percent E-Z entry seat backrest. For additional information, refer to
Seat Backrest - Second Row, 60 Percent, E-Z Entry
See: Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 60 Percent, E-Z Entry.
9. Install the second row, 60 percent E-Z entry seat into the vehicle. For additional information,
refer to Seat - Second Row, 60/40, E-Z Entry See:
Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry.
10. Cycle the backrest down and then back to the upright position. Make sure the inboard and
outboard recliners simultaneously and securely
lock in the upright position.
Seat Recliner - Outboard, Second Row, 60 Percent E-Z Entry
Seat Recliner - Outboard, Second Row, 60 Percent E-Z Entry
Removal
1. Remove the second row, 60 percent E-Z entry seat from the vehicle. For additional information,
refer to Seat - Second Row, 60/40, E-Z Entry
See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry.
2. Remove the second row, 60 percent E-Z entry seat backrest. For additional information, refer to
Seat Backrest - Second Row, 60 Percent, E-Z
Entry See: Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 60 Percent, E-Z
Entry.
3. Remove 3 screws, recliner handle and outboard recliner outer cover.
4. Remove the 2 outboard recliner-to-backrest frame bolts.
5. NOTE: When pulling outboard recliner out, note keyed position of recliner release shaft as it may
pull out of inboard recliner.
Remove 2 outboard recliner-to-cushion frame bolts, pull out and separate the outboard recliner.
6. Remove the outboard recliner inner cover.
7. Remove the outboard recliner.
1. Rotate the cable casing out of the outboard recliner.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7856
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.
Installation
1. If necessary, position the recliner release shaft onto the inboard recliner release pivot stub.
2. NOTE: The cable ends are color coded/keyed to the levers.
Position each keyed cable end to the outboard recliner lever and rotate into position.
- Install the cable casing to the outboard recliner.
3. Install the outboard recliner inner cover.
4. Position the outboard recliner release pivot stub into the recliner shaft.
5. Install the 2 outboard recliner-to-cushion frame bolts.
- Tighten to 55 Nm (41 lb-ft).
6. Install the second row, 60 percent E-Z entry seat backrest. For additional information, refer to
Seat Backrest - Second Row, 60 Percent, E-Z Entry
See: Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 60 Percent, E-Z Entry.
7. Install the second row, 60 percent E-Z entry seat into the vehicle. For additional information,
refer to Seat - Second Row, 60/40, E-Z Entry See:
Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry.
8. Cycle the backrest down and then back to the upright position. Make sure the inboard and
outboard recliners simultaneously and securely
lock in the upright position.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7857
Seat - Exploded View, Third Row
Seat - Exploded View, Third Row
Third Row Seat Backrest
NOTE: RH backrest shown, LH similar.
NOTE: Power latch shown, manual latch similar.
Third Row Seat Cushion
NOTE: RH cushion shown, LH similar.
NOTE: Power latch shown, manual latch similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7858
1. For additional information, refer to the procedures.
Seat Backrest - Third Row
Seat Backrest - Third Row
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7859
4. Release the backrest trim cover lower J-clip on the backrest being serviced.
5. NOTICE: Use care when separating the backrest trim cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from
the backrest foam pad.
Release the backrest trim cover side J-clips, hook-and-loop strips and invert the trim cover to
expose the 2 hinge-to-backrest frame bolts and the 2 latch-to-backrest frame bolts on the backrest
being serviced.
Manual fold seats
6. Separate the cable casing from the latch and remove the cable from the latch lever on the
backrest being serviced.
All seats
7. Remove the 2 hinge-to-backrest frame bolts and the 2 latch-to-backrest frame bolts and remove
the backrest.
- To install, tighten to 25 Nm (18 lb-ft).
8. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7860
Seat Back: Overhaul
Front Seats
Seat Backrest - Front
Front Seat Backrest
NOTE: Driver backrest shown, passenger backrest similar.
Disassembly
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7861
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.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
WARNING: 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.
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: 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.
NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
NOTE: The manual recliners and power recliners are serviced as part of the backrest frame.
All seats
1. Remove the front seat. For additional information, refer to Seat - Front See: Service and
Repair/Front Seats/Seat - Front.
2. Remove the front seat backrest. For additional information, refer to Seat Backrest - Front See:
Removal and Replacement/Front Seats/Seat
Backrest - Front.
3. Remove the 2 head restraint guide sleeves. For additional information, refer to Head Restraint
Guide Sleeve See: Head Rest/Service and Repair.
4. Remove the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners.
5. NOTICE: 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. Remove the backrest trim cover.
Heated seat
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7862
9. 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
10. Separate the backrest foam pad from the backrest frame.
11. 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
12. Release the 2 manual lumbar spring clips from the backrest frame and remove the manual
lumbar.
Seat with power lumbar
13. 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
14. NOTICE: Do not rotate the recliner shaft while not engaged to both recliners. Failure to do so
will cause the inboard and outboard
recliners to become out of synchronization.
Remove a one-way push clip from the recliner shaft and remove the recliner shaft.
15. Disconnect the electrical connector, remove the screw and the power recline motor.
Assembly
Seat with power recline
1. NOTICE: Do not rotate the recliner shaft while not engaged to both recliners. Failure to do so will
cause the inboard and outboard
recliners to become out of synchronization.
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7863
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.
WARNING: 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.
WARNING: 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.
NOTICE: 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7864
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. Install the 2 head restraint guide sleeves. For additional information, refer to Head Restraint
Guide Sleeve See: Head Rest/Service and Repair.
15. Install the front seat backrest. For additional information, refer to Seat Backrest - Front See:
Removal and Replacement/Front Seats/Seat Backrest
- Front.
16. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this
time. For additional information, refer to Seat Front See: Service and Repair/Front Seats/Seat - Front.
Passenger seat
17. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS. For additional information, refer to
General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing
and Inspection/Component Tests and General Diagnostics
Seat Backrest - Second Row, 40 Percent E-Z Entry
Seat Backrest - Second Row, 40 Percent E-Z Entry
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7865
Disassembly and Assembly
1. Remove the second row, 40 percent E-Z entry seat from the vehicle. For additional information,
refer to Seat - Second Row, 60/40, E-Z Entry
See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry.
2. Remove the second row, 40 percent E-Z entry seat backrest. For additional information, refer to
Seat Backrest - Second Row, 40 Percent E-Z
Entry See: Removal and Replacement/Second Row Seating/Seat Backrest/Seat Backrest - Second
Row, 40 Percent E-Z Entry.
3. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and
remove the head restraint.
4. NOTICE: Use care when separating the backrest 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7866
6. Remove the backrest trim cover.
7. Separate the backrest foam pad from the backrest frame.
8. To assemble, reverse the disassembly procedure.
Seat Backrest - Second Row, 60 Percent, E-Z Entry
Seat Backrest - Second Row, 60 Percent, E-Z Entry
Second Row, 60 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7867
Disassembly
1. Remove the second row, 60 percent E-Z entry seat. For additional information, refer to Seat Second Row, 60/40, E-Z Entry See: Service and
Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry.
2. Remove the second row, 60 percent E-Z entry seat backrest. For additional information, refer to
Seat Backrest - Second Row, 60 Percent, E-Z
Entry See: Removal and Replacement/Second Row Seating/Seat Backrest/Seat Backrest - Second
Row, 60 Percent, E-Z Entry.
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. NOTICE: Use care when separating the backrest 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7868
10. Remove the bolt, safety belt retractor and insulator.
- To install, tighten to 75 Nm (55 lb-ft).
- If necessary, remove the safety belt retractor insulator.
11. To assemble, reverse the disassembly procedure.
Seat Backrest - Second Row, 40 Percent, Bench
Seat Backrest - Second Row, 40 Percent, Bench
Disassembly and Assembly
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7869
1. Remove the second row 60 percent seat of the 60/40 bench seat. For additional information,
refer to Seat - Second Row, Sport Trac or Seat Second Row, Explorer, 60/40 Bench See: Service and Repair/Second Row Seating/Seat - Second
Row, 60/40 Bench.
2. Remove the second row, 40 percent seat backrest. For additional information, refer to Seat
Backrest - Second Row, 40 Percent, Bench See:
Removal and Replacement/Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 40
Percent, Bench.
3. Remove the screw and the release handle.
4. Remove the 3 screws and the latch cover.
5. Remove the bolt and the safety belt buckle.
- To install, tighten to 55 Nm (41 lb-ft).
6. Remove the head restraint.
7. NOTE: The inboard and outboard head restraint sleeves are not interchangeable.
NOTE: 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. NOTICE: Use care when separating the backrest 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. NOTICE: Do not detach the latch cable from the seat latches. The latch assembly is
synchronized; if disassembled, the latch assembly
may not operate correctly.
Remove the latch assembly.
- Do not separate or disassemble the latch assembly components.
13. To assemble, reverse the disassembly procedure.
Seat Backrest - Second Row, 60 Percent, Bench
Seat Backrest - Second Row, 60 Percent, Bench
Explorer/Mountaineer, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7870
Explorer Sport Trac, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7871
Disassembly and Assembly
1. Remove the second row 60 percent seat of the 60/40 bench seat. For additional information,
refer to Seat - Second Row, Sport Trac or Seat Second Row, Explorer, 60/40 Bench See: Service and Repair/Second Row Seating/Seat - Second
Row, 60/40 Bench.
2. Remove the second row, 60 percent seat backrest. For additional information, refer to Seat
Backrest - Second Row, 60 Percent, Bench See:
Removal and Replacement/Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 60
Percent, Bench.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7872
3. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and
remove the head restraint.
4. NOTE: The inboard and outboard head restraint sleeves are not interchangeable.
NOTE: 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. For Explorer and Mountaineer, pull at the bottom and remove the safety belt guide cover.
6. NOTICE: Use care when separating the backrest 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 and 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. Remove the seat tether-to-riser frame nut and the seat tether (if equipped).
- To install, tighten to 55 Nm (41 lb-ft).
11. Remove the screw and the release handle.
12. Remove the 3 screws and the outboard latch cover.
13. Remove the outboard latch-to-riser frame bolts.
- To install, tighten to 40 Nm (30 lb-ft). For Sport Trac, remove the outboard and upper latch assembly.
14. NOTICE: For Explorer and Mountaineer, 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 inboard latch-to-riser frame front bolt. For Explorer and Mountaineer, remove the latch
assembly. For Sport Trac, remove the inboard latch.
- To install, tighten to 121 Nm (89 lb-ft).
15. To assemble, reverse the disassembly procedure.
Seat Backrest - Second Row, Bucket
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7873
Seat Backrest - Second Row, Bucket
Disassembly and Assembly
1. Remove the second row, 40 percent bucket seat backrest. For additional information, refer to
Seat Backrest - Second Row, Bucket See: Removal
and Replacement/Second Row Seating/Seat Backrest/Seat Backrest - Second Row, Bucket.
2. Remove the head restraint.
3. NOTICE: Use care when separating the backrest 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.
NOTE: 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.
Third Row Seating
Seat Backrest - Third Row
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7874
Third Row Seat Backrest
NOTE: RH backrest shown, LH similar.
Disassembly and Assembly
All seats
1. Remove the seat backrest. For additional information, refer to Seat Backrest - Third Row See:
Removal and Replacement/Third Row Seating/Seat
Backrest - Third Row.
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).
Manual fold seats
4. Release the 3 backrest release handle clips and separate from the backrest.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 7875
All seats
5. NOTICE: Use care when separating the backrest trim cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from
the backrest foam pad.
Release the hook-and-loop strips, invert and remove the backrest trim cover.
- If equipped, route the backrest release handle and cable through the backrest trim cover.
Manual fold seats
6. Route the backrest release cable out of the backrest frame and remove the backrest release
handle and cable.
All seats
7. Separate the backrest foam pad from the backrest frame.
8. To assemble, reverse the disassembly procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats
Seat Cover: Service and Repair Front Seats
Seat - Exploded View, Front
Seat - Exploded View, Front
Front Seat Backrest
NOTE: Driver backrest shown, passenger backrest similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7880
Driver Seat Cushion
NOTE: Power seat track shown, manual seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7881
Passenger Seat Cushion
NOTE: Manual seat track shown, power seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7882
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7883
1. For additional information, refer to the procedures.
Seat Backrest Cover - Front
Seat Backrest Cover - Front
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.
All seats
1. Remove the front seat. For additional information, refer to Seat - Front See: Service and
Repair/Front Seats/Seat - Front.
2. Remove the front seat backrest. For additional information, refer to Seat Backrest - Front See:
Seat Back/Service and Repair/Removal and
Replacement/Front Seats/Seat Backrest - Front.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7884
3. Remove the 2 head restraint guide sleeves. For additional information, refer to Head Restraint
Guide Sleeve See: Head Rest/Service and Repair.
4. Remove the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners.
5. NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7885
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Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7886
Seat Cover: Service and Repair Second Row Seating
Seat - Exploded View, Second Row
Seat - Exploded View, Second Row
60 Percent E-Z Entry Backrest
60 Percent, E-Z Entry Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7887
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7888
40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7889
40 Percent, E-Z Entry Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7890
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7891
Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7892
Bucket, Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7893
Explorer/Mountaineer, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7894
Explorer Sport Trac, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7895
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7896
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7897
Second Row, 40 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7898
1. For additional information, refer to the procedures.
Seat Backrest Cover - Second Row, Bucket
Seat Backrest Cover - Second Row, Bucket
Removal and Installation
1. Remove the head restraint.
2. NOTICE: Use care when separating the backrest 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, separate the hook-and-loop fasteners, remove 2 rows
of hog rings and invert the backrest trim cover as high as it will go.
3. NOTE: The inboard and outboard head restraint sleeves are not interchangeable.
NOTE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7899
4. Remove the seat backrest trim cover.
5. To install, reverse the removal procedure.
Seat Backrest Cover - Second Row, 40 Percent E-Z Entry
Seat Backrest Cover - Second Row, 40 Percent E-Z Entry
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.
2. NOTICE: 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. NOTICE: Use care when separating the seat back trim cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from
the backrest foam pad.
Release the hook-and-loop strips and invert the trim cover as high as it will go.
- Pull the kneeling mechanism release handle and cable through the backrest trim cover opening.
5. From between the backrest foam pad and the backrest frame, reach up, pinch the ends together
and remove the head restraint guides.
6. Remove the backrest trim cover.
7. To install, reverse the removal procedure.
Seat Backrest Cover - Second Row, 40 Percent, Bench
Seat Backrest Cover - Second Row, 40 Percent, Bench
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7900
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.
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.
NOTE: 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. NOTICE: Use care when separating the seat backrest 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.
7. To install, reverse the removal procedure.
Seat Backrest Cover - Second Row, 60 Percent, Bench
Seat Backrest Cover - Second Row, 60 Percent, Bench
Removal and Installation
All vehicles
1. Remove the second row 60 percent seat of the 60/40 bench seat. For additional information,
refer to Seat - Second Row, Sport Trac or Seat Second Row, Explorer, 60/40 Bench See: Service and Repair/Second Row Seating/Seat - Second
Row, 60/40 Bench.
2. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and
remove the head restraint.
3. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
Remove the safety belt anchor bolt.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7901
- To install, tighten to 121 Nm (89 lb-ft).
4. Remove the safety belt guide cover in the following sequence.
1. Pull out at the bottom and release the 2 safety belt guide cover retainers.
2. Tip the bottom of the safety belt guide cover up to release the top retainer and remove the safety
belt guide cover.
Sport Trac vehicles
5. Remove the retainers and the upper latch cover.
All vehicles
6. Release the backrest trim cover J-clip.
7. Remove all the staples in the backrest support panel.
8. Reposition the backrest trim cover and foam pad to access the latch cover screws.
9. Remove the latch covers in the following sequence.
1. Remove the 4 latch cover screws.
2. Detach the backrest trim cover from the latch covers.
3. Remove the latch covers.
10. NOTICE: Use care when separating the backrest 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 and invert the backrest trim cover.
11. NOTE: The inboard and outboard head restraint sleeves are not interchangeable.
NOTE: 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.
12. Remove the backrest trim cover.
- Feed the safety belt out through the opening in the backrest trim cover.
13. To install, reverse the removal procedure.
Seat Backrest Cover - Second Row, 60 Percent, E-Z Entry
Seat Backrest Cover - Second Row, 60 Percent, E-Z Entry
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7902
Removal
1. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and
remove the head restraint.
2. Remove 2 screws and the inboard recliner outer cover.
3. NOTICE: 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. NOTICE: 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
Seat Cushion Cover - Second Row, Bucket
Seat Cushion Cover - Second Row, Bucket
Removal and Installation
1. NOTICE: 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 cushion trim cover J-clips, separate the hook-and-loop fasteners and remove one row
of hog rings.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7903
2. Release the cable from the seat riser and remove the cushion trim cover.
3. To install, reverse the removal procedure.
Seat Cushion Cover - Second Row, 40 Percent E-Z Entry
Seat Cushion Cover - Second Row, 40 Percent E-Z Entry
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. NOTICE: 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.
4. To install, reverse the removal procedure.
- Make sure the lower anchor and tethers for children wires at the rear of the cushion frame are
positioned through the cushion trim cover and accessible for use after installation.
Seat Cushion Cover - Second Row, 40 Percent, Bench
Seat Cushion Cover - Second Row, 40 Percent, Bench
Removal and Installation
1. Remove the second row 40 percent seat of the 60/40 bench seat. For additional information,
refer to Seat - Second Row, Sport Trac or Seat Second Row, Explorer, 60/40 Bench See: Service and Repair/Second Row Seating/Seat - Second
Row, 60/40 Bench.
2. NOTICE: 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.
Seat Cushion Cover - Second Row, 60 Percent, Bench
Seat Cushion Cover - Second Row, 60 Percent, Bench
Removal and Installation
1. Remove the second row 60 percent seat of the 60/40 bench seat. For additional information,
refer to Seat - Second Row, Sport Trac or Seat Second Row, Explorer, 60/40 Bench See: Service and Repair/Second Row Seating/Seat - Second
Row, 60/40 Bench.
2. NOTICE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7904
Seat Cushion Cover - Second Row, 60 Percent, E-Z Entry
Seat Cushion Cover - Second Row, 60 Percent, E-Z Entry
Removal
1. Remove the 2 screws and the latch feet release bar.
2. Release all the cushion trim cover retainers and pin-type retainers.
3. NOTICE: 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.
4. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
To install, reverse the removal procedure.
- Make sure the lower anchor and tethers for children wires at the rear of the cushion frame are
positioned through the cushion trim cover and accessible for use after installation.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7905
Seat Cover: Service and Repair Third Row Seating
Seat - Exploded View, Third Row
Seat - Exploded View, Third Row
Third Row Seat Backrest
NOTE: RH backrest shown, LH similar.
NOTE: Power latch shown, manual latch similar.
Third Row Seat Cushion
NOTE: RH cushion shown, LH similar.
NOTE: Power latch shown, manual latch similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7906
1. For additional information, refer to the procedures.
Seat Backrest Cover - Third Row
Seat Backrest Cover - Third Row
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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front
Seats > Page 7907
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. NOTICE: Use care when separating the backrest 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
Removal and Installation
1. Remove the third row seat from the vehicle. For additional information, refer to Seat - Third Row
See: Service and Repair/Third Row
Seating/Seat - Third Row.
2. Release the cushion trim cover retainers attached to the bottom of the cushion frame.
3. NOTICE: 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.
Invert the cushion trim cover, release the hook-and-loop strips and separate the cushion trim cover
from the cushion foam pad.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal and Installation
1. Position the backrest to the upright position.
2. Remove the third row seat from the vehicle. For additional information, refer to Seat - Third Row
See: Service and Repair/Third Row
Seating/Seat - Third Row.
3. NOTE: The backrest must be up to access the bolts.
Remove the latch-to-cushion frame bolt and the hinge-to-cushion frame bolt.
- To install, tighten to 25 Nm (18 lb-ft).
4. From under the front of the cushion frame, release the cushion trim cover from the studs to
access the 2 cushion pivot link assembly-to-cushion
frame nuts.
5. Remove the 2 cushion pivot link assembly-to-cushion frame nuts. Remove the cushion
assembly.
- To install, tighten to 22 Nm (16 lb-ft).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7912
Seat Cushion: Overhaul
Front Seats
Seat Cushion - Front
Driver Seat Cushion
NOTE: Power seat track shown, manual seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7913
Passenger Seat Cushion
NOTE: Manual seat track shown, power seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7914
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7915
Disassembly and Assembly
All seats
1. Remove the front seat. For additional information, refer to Seat - Front See: Service and
Repair/Front Seats/Seat - Front.
2. Remove the seat track. For additional information, refer to Seat Track See: Seat Track/Service
and Repair/Seat Track.
3. Remove the front seat backrest. For additional information, refer to Seat Backrest - Front See:
Seat Back/Service and Repair/Removal and
Replacement/Front Seats/Seat Backrest - Front.
4. NOTICE: 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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7916
All seats
6. To assemble, reverse the disassembly procedure.
7. Install the front seat backrest. For additional information, refer to Seat Backrest - Front See: Seat
Back/Service and Repair/Removal and
Replacement/Front Seats/Seat Backrest - Front.
8. Install the seat track. For additional information, refer to Seat Track See: Seat Track/Service and
Repair/Seat Track.
9. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this
time. For additional information, refer to Seat Front See: Service and Repair/Front Seats/Seat - Front.
Passenger seat
10. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS. For additional information, refer to
General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing
and Inspection/Component Tests and General Diagnostics
Seat Cushion - Second Row, 40 Percent E-Z Entry
Seat Cushion - Second Row, 40 Percent E-Z Entry
Second Row, 40 Percent, E-Z Entry Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7917
Disassembly
1. Remove the second row 40 percent E-Z entry seat from the vehicle. For additional information,
refer to Seat - Second Row, 60/40, E-Z Entry See:
Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7918
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.
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. For additional information, refer to
Seat Backrest - Second Row, 40 Percent E-Z Entry
See: Seat Back/Service and Repair/Removal and Replacement/Second Row Seating/Seat
Backrest/Seat Backrest - Second Row, 40 Percent E-Z Entry.
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. NOTICE: Use care when separating the cushion trim cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from the
cushion foam pad.
Release the hook-and-loop strips and separate the cushion trim cover from the cushion foam pad.
12. Remove 2 outboard recliner-to-cushion frame bolts and separate the outboard recliner.
13. Remove the outboard recliner inner cover.
14. Remove the outboard recliner.
1. Rotate the cable casing out of the outboard recliner.
2. NOTE: The cable ends are color coded/keyed to the levers.
Rotate the cable ends out of the outboard recliner levers.
3. Remove the outboard recliner.
15. Remove the 2 screws, pull to separate and remove the kneeling mechanism inboard leg inner
and outer covers.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7919
16. Separate the cable to the kneeling mechanism inboard leg.
1. Turn and separate the cable casing retainer at the inboard side of the kneeling mechanism
inboard leg.
2. Separate the cable from the kneeling mechanism inboard leg release lever.
- Remove any cable casing retainers.
17. Remove 2 bolts, the spacer and the latch feet retracting link.
18. Remove the 2 screws and the 2 latch foot covers.
19. Separate the cable and casing from the outboard latch foot. Remove the cable assembly.
20. Remove the screw and separate the kneeling mechanism release cable pivot at the inboard
recliner.
21. Remove the 2 screws, pull to separate and remove the kneeling mechanism outboard leg inner
and outer covers.
22. Separate the cable to the kneeling mechanism outboard leg and cushion frame.
1. Turn and separate the cable casing retainer at the inboard side of the outboard kneeling
mechanism leg.
2. Separate the cable from the outboard kneeling mechanism leg release lever.
3. Separate any cable casing retainers to the cushion frame and remove the cable.
23. Remove the 2 inboard recliner-to-cushion frame bolts, the safety belt buckle and separate the
inboard recliner with recliner release shaft.
- If necessary, separate the recliner release shaft from the inboard recliner.
24. Remove the inboard recliner inner cover.
25. Remove the cushion frame.
- Remove the 2 kneeling mechanism-to-cushion frame bolts.
- Remove the 2 latch feet assembly-to-cushion frame bolt.
- Remove the cushion frame.
26. Using the release lever, manually release the inboard and outboard latch feet and remove the
latch feet assembly.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7920
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.
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7921
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.
10. Route the kneeling mechanism release cable, position the cable pivot at the inboard recliner
and install the screw.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7922
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 lower anchor and tethers for children wires at the rear of the cushion frame are
positioned through the cushion trim cover and accessible for use after installation.
19. Position the latch feet release bar and install the 2 screws.
20. Install the second row, 40 percent E-Z entry seat backrest. For additional information, refer to
Seat Backrest - Second Row, 40 Percent E-Z Entry
See: Seat Back/Service and Repair/Removal and Replacement/Second Row Seating/Seat
Backrest/Seat Backrest - Second Row, 40 Percent E-Z Entry.
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. For additional information,
refer to Seat - Second Row, 60/40, E-Z Entry See:
Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry.
25. Cycle the backrest down and then back to the upright position. Make sure the inboard and
outboard recliners simultaneously and securely
lock in the upright position.
Seat Cushion - Second Row, 60 Percent, E-Z Entry
Seat Cushion - Second Row, 60 Percent, E-Z Entry
Second Row, 60 Percent, E-Z Entry Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7923
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7924
Disassembly
1. Remove the second row, 60 percent E-Z entry seat from the vehicle. For additional information,
refer to Seat - Second Row, 60/40, E-Z Entry
See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7925
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.
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. For additional information, refer to
Seat Backrest - Second Row, 60 Percent, E-Z
Entry See: Seat Back/Service and Repair/Removal and Replacement/Second Row Seating/Seat
Backrest/Seat Backrest - Second Row, 60 Percent, E-Z Entry.
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. NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7926
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.
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7927
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 (V6-4.0L (2009))
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Removal and Replacement > Page 7928
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 40 Nm (30 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 55 Nm (41 lb-ft).
- Install the inboard recliner-to-cushion frame front bolt. Tighten to 55 Nm (41 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.
11. Install the outboard recliner inner cover.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7929
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.
15. Route the kneeling mechanism release cable, position the kneeling mechanism release cable
pivot at the inboard recliner and attach all cable casing
retainers.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7930
16. Make sure the inboard recliner pin is through the cable pivot.
17. Install the kneeling mechanism release cable to the kneeling mechanism outboard leg.
- Attach the cable to the kneeling mechanism outboard leg release lever.
- Position, turn and install the cable casing retainer at the inboard side of the kneeling mechanism
outboard leg.
- Attach any cable casing retainers.
18. Position the inner and outer covers around the kneeling mechanism outboard leg and install the
2 screws.
19. Position the inner and outer covers around the kneeling mechanism inboard leg and install the
2 screws.
20. Position the 2 latch foot covers and install the 2 screws.
21. Position the latch feet retracting link retainer onto the latch feet retracting link shaft.
22. Position the latch feet retracting link into the kneeling mechanism coupler engaging the
retainer.
- The kneeling mechanism coupler is part of the kneeling mechanism.
23. Slide the latch feet retracting link retainer back to the kneeling mechanism coupler, engaging
the retainer.
24. Position the spacer between the latch feet retracting link and outboard latch foot and install the
bolt.
25. Align the safety belt buckle anti-rotation tabs to the cushion frame openings and install the 2
bolts.
- Tighten to 40 Nm (30 lb-ft).
26. Align the cushion trim cover to the cushion foam pad and attach the hook-and-loop strips.
27. Position the cushion foam pad and trim cover to the cushion frame and attach the cushion trim
cover retainers and pin-type retainers.
- Pull the 2 safety belt buckles through the cushion trim cover and foam pad.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Removal and Replacement > Page 7931
- Make sure the lower anchor and tethers for children wires at the rear of the cushion frame are
positioned through the cushion trim cover and accessible for use after installation.
28. Position the latch feet release bar and install the 2 screws.
29. Install the second row, 60 percent E-Z entry seat backrest. For additional information, refer to
Seat Backrest - Second Row, 60 Percent, E-Z Entry
See: Seat Back/Service and Repair/Removal and Replacement/Second Row Seating/Seat
Backrest/Seat Backrest - Second Row, 60 Percent, E-Z Entry.
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. For additional information,
refer to Seat - Second Row, 60/40, E-Z Entry See:
Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry.
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.
Seat Cushion - Second Row, 40 Percent, Bench
Seat Cushion - Second Row, 40 Percent, Bench
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7932
Disassembly and Assembly
1. Remove the second row 40 percent seat of the 60/40 bench seat. For additional information,
refer to Seat - Second Row, Sport Trac or Seat Second Row, Explorer, 60/40 Bench See: Service and Repair/Second Row Seating/Seat - Second
Row, 60/40 Bench.
2. Remove the second row, 40 percent bench seat backrest. For additional information, refer to
Seat Backrest - Second Row, 40 Percent, Bench See:
Seat Back/Service and Repair/Removal and Replacement/Second Row Seating/Seat
Backrest/Seat Backrest - Second Row, 40 Percent, Bench.
3. NOTICE: 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
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.
Seat Cushion - Second Row, 60 Percent, Bench
Seat Cushion - Second Row, 60 Percent, Bench
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7933
Disassembly and Assembly
1. Remove the second row 60 percent seat of the 60/40 bench seat. For additional information,
refer to Seat - Second Row, Sport Trac or Seat Second Row, Explorer, 60/40 Bench See: Service and Repair/Second Row Seating/Seat - Second
Row, 60/40 Bench.
2. Remove the second row 60 percent bench seat backrest. For additional information, refer to
Seat Backrest - Second Row, 60 Percent, Bench See:
Seat Back/Service and Repair/Removal and Replacement/Second Row Seating/Seat
Backrest/Seat Backrest - Second Row, 60 Percent, Bench.
3. Remove the inboard upper pivot latch bolt.
- To install, tighten to 40 Nm (30 lb-ft).
4. NOTICE: 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.
5. Remove the cushion foam pad.
6. Remove 2 cushion pad supports.
7. To assemble, reverse the disassembly procedure.
Seat Cushion - Second Row, Bucket
Seat Cushion - Second Row, Bucket
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Removal and Replacement > Page 7934
Disassembly and Assembly
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7935
NOTE: LH seat shown, RH similar.
1. Remove the second row bucket seat. For additional information, refer to Seat - Second Row,
Bucket See: Service and Repair/Second Row
Seating/Seat - Second Row, Bucket.
2. Remove the second row bucket seat backrest. For additional information, refer to Seat Backrest
- Second Row, Bucket See: Seat Back/Service
and Repair/Removal and Replacement/Second Row Seating/Seat Backrest/Seat Backrest Second Row, Bucket.
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. NOTICE: 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
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).
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.
Third Row Seating
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7936
Seat Cushion - Third Row
Third Row Seat Cushion
NOTE: RH cushion shown, LH similar.
NOTE: Power latch shown, manual latch similar.
Disassembly and Assembly
1. Remove the third row seat from the vehicle. For additional information, refer to Seat - Third Row
See: Service and Repair/Third Row
Seating/Seat - Third Row.
2. Remove the third row cushion. For additional information, refer to Seat Cushion - Third Row
See: Removal and Replacement.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 7937
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. NOTICE: Use care when separating the backrest trim cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from
the backrest foam pad.
Invert the cushion trim cover, release the hook-and-loop strips and separate the cushion trim cover
from the cushion foam pad.
6. To assemble, reverse the disassembly procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions
Seat Heater: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information and Instructions > Page 7942
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information and Instructions > Page 7943
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 7944
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 7945
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
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 7946
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery 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 loose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information and Instructions > Page 7947
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 7948
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 7949
Symbols (Part 4)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information and Instructions > Page 7950
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information and Instructions > Page 7951
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.
Defective insulation stripping
1 = Proper crimp
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information and Instructions > Page 7952
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
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Information and Instructions > Page 7953
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 7954
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 7955
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 7956
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.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 7957
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 7958
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 7959
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 7960
Seat Heater: Connector Views
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 7961
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 7962
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 7963
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 7964
Seat Heater: Service and Repair
Seat - Exploded View, Front
Front Seat Backrest
NOTE: Driver backrest shown, passenger backrest similar.
Driver Seat Cushion
NOTE: Power seat track shown, manual seat track similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 7965
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 7966
Passenger Seat Cushion
NOTE: Manual seat track shown, power seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 7967
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 7968
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and
Repair
Seat Heater Control Module: Service and Repair
Seat - Exploded View, Front
Front Seat Backrest
NOTE: Driver backrest shown, passenger backrest similar.
Driver Seat Cushion
NOTE: Power seat track shown, manual seat track similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and
Repair > Page 7972
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and
Repair > Page 7973
Passenger Seat Cushion
NOTE: Manual seat track shown, power seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and
Repair > Page 7974
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and
Repair > Page 7975
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page
7979
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch
Seat Heater Switch: Service and Repair Heated Seat Switch
Heated Seat Switch
Removal and Installation
1. Position the gear selector to NEUTRAL.
2. Remove the console trim ring.
3. Open the center console door, remove the 2 screws and pull up on the console finish panel to
release the retainers.
4. Disconnect the power point electrical connector and remove the console finish panel.
5. Pull out to release the retainers and separate the instrument panel center lower RH and LH
finish panels.
6. Pull out to release the retainers and separate the instrument panel center finish panel.
7. Disconnect the electrical connector, release the 4 tabs and remove the heated seat/heated
windshield switch pack.
8. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 7982
Seat Heater Switch: Service and Repair Seat - Exploded View, Front
Seat - Exploded View, Front
Front Seat Backrest
NOTE: Driver backrest shown, passenger backrest similar.
Driver Seat Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 7983
NOTE: Power seat track shown, manual seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 7984
Passenger Seat Cushion
NOTE: Manual seat track shown, power seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 7985
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 7986
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating
Seat Latch: Service and Repair Second Row Seating
Seat - Exploded View, Second Row
60 Percent E-Z Entry Backrest
60 Percent, E-Z Entry Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating > Page 7991
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating > Page 7992
40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating > Page 7993
40 Percent, E-Z Entry Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating > Page 7994
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating > Page 7995
Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating > Page 7996
Bucket, Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating > Page 7997
Explorer/Mountaineer, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating > Page 7998
Explorer Sport Trac, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating > Page 7999
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating > Page 8000
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating > Page 8001
Second Row, 40 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating > Page 8002
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating > Page 8003
Seat Latch: Service and Repair Third Row Seating
Seat - Exploded View, Third Row
Seat - Exploded View, Third Row
Third Row Seat Backrest
NOTE: RH backrest shown, LH similar.
NOTE: Power latch shown, manual latch similar.
Third Row Seat Cushion
NOTE: RH cushion shown, LH similar.
NOTE: Power latch shown, manual latch similar.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating > Page 8004
1. For additional information, refer to the procedures.
Seat Latch - Third Row, Manual
Seat Latch - Third Row, Manual
Removal and Installation
LH or RH latch
1. Position both of the third row seat backrests up.
2. Remove the RH latch-to-cushion frame bolt.
- To install, tighten to 25 Nm (18 lb-ft).
LH latch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating > Page 8005
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. NOTICE: Use care when separating the backrest trim cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from
the backrest foam pad.
Release the RH seat backrest trim cover lower and inboard J-clips and roll the backrest trim cover
up to access the 2 RH latch-to-backrest frame bolts.
10. Remove the 2 RH latch-to-backrest frame bolts.
- To install, tighten to 25 Nm (18 lb-ft).
11. Remove the floor mounting bracket center front and rear nuts.
- To install, tighten to 40 Nm (30 lb-ft).
12. Remove the 2 latch-to-floor mounting bracket nuts.
- To install, tighten to 22 Nm (16 lb-ft).
13. Remove the RH latch.
LH latch
14. Position the third row seat LH backrest up and the RH backrest down.
15. Remove the 2 screws and the LH latch cover.
16. Separate the cable and casing from the LH latch.
17. NOTICE: Use care when separating the backrest 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second
Row Seating > Page 8006
21. To install, reverse the removal procedure.
- The latch(es) must be in the backrest fold down position to install.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track
Seat Track: Service and Repair Seat Track
Seat Track
Removal and Installation
All seats
1. Remove the front seat. For additional information, refer to Seat - Front See: Service and
Repair/Front Seats/Seat - Front.
Passenger seat with failed horizontal motor
2. To remove the Occupant Classification Sensor (OCS) rails, remove the 2 horizontal screw block
bolts. This will allow the power seat tracks to
move independently of each other for access to the 8 OCS rail bolts.
Passenger seat receiving a new seat track
3. Remove the inboard and outboard OCS rails. For additional information, refer to Occupant
Classification Sensor (OCS) in the removal and
installation portion of Air Bag Systems.
Passenger seat not receiving a new seat track
4. NOTE: Note the position and the routing of the OCS 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. Remove the clip and manual recline handle (if equipped).
2. Pull and remove the manual lumbar control knob (if equipped).
3. Remove the scrivet.
4. Remove the retention bracket screw and the retention bracket (if equipped).
5. Release the cushion side shield front clip.
6. From under the cushion side shield, release the 3 hook retainers.
7. Pull out on the cushion side shield at the back and release the pin-type retainer.
8. Separate the cushion trim cover elastic strap from the cushion side shield.
- With manual seat track, remove the cushion side shield.
9. With power seat track, remove the seat control switch knob and separate the seat control switch
from the cushion side shield.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track > Page 8011
- 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.
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 (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track > Page 8012
- 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. For additional information, refer to Seat Front See: Service and Repair/Front Seats/Seat - Front.
Passenger seat
19. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS. For additional information, refer to
General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing
and Inspection/Component Tests and General Diagnostics
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track > Page 8013
Seat Track: Service and Repair Seat - Exploded View, Front
Seat - Exploded View, Front
Front Seat Backrest
NOTE: Driver backrest shown, passenger backrest similar.
Driver Seat Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track > Page 8014
NOTE: Power seat track shown, manual seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track > Page 8015
Passenger Seat Cushion
NOTE: Manual seat track shown, power seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track > Page 8016
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track > Page 8017
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information >
Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information >
Locations > Page 8021
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Locations > Page 8026
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Door Lock Switch, Passenger Side
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8031
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Door Lock Switch, Driver Side
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8034
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 8035
Power Door Lock Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 8036
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 8037
Power Door Lock Switch: Service and Repair
Door Lock Control Switch
Removal and Installation
NOTE: The LH side is shown, the RH side is similar.
1. Remove the interior door handle cover.
2. Remove the front door switch bezel.
- Release the 4 retaining tabs.
3. Disconnect the door lock control switch and window control switch electrical connectors.
4. Remove the door lock control switch.
- Release the 4 retaining tabs.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 8041
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 8042
Power Mirror Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 8043
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 8044
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 8045
Power Mirror Switch: Service and Repair
Exterior Mirror Control Switch
Removal and Installation
1. Remove the front door trim panel.
2. Depress the 2 retaining tabs and remove the exterior mirror control switch from the front door
trim panel.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Third Row Folding Seat Switch, Left
Power Seat Switch: Locations Third Row Folding Seat Switch, Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Third Row Folding Seat Switch, Left > Page 8050
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Third Row Folding Seat Switch, Left > Page 8051
Power Seat Switch: Locations Third Row Folding Seat Switch, Right
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Third Row Folding Seat Switch, Left > Page 8052
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Third Row Folding Seat Switch, Left > Page 8053
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Third Row Folding Seat Switch, Left > Page 8054
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Power Seat Switch, Left
Power Seat Switch: Diagrams Power Seat Switch, Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Power Seat Switch, Left > Page 8057
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Power Seat Switch, Left > Page 8058
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Power Seat Switch, Left > Page 8059
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Power Seat Switch, Left > Page 8060
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat
Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 6-Way Power Seat
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 8063
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 8064
Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 10-Way Power Seat
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 8065
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 8066
Power Seat Switch: Testing and Inspection Power Seat Switch, Right
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 8067
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat - Exploded View, Front
Power Seat Switch: Service and Repair Seat - Exploded View, Front
Seat - Exploded View, Front
Front Seat Backrest
NOTE: Driver backrest shown, passenger backrest similar.
Driver Seat Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat - Exploded View, Front > Page 8070
NOTE: Power seat track shown, manual seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat - Exploded View, Front > Page 8071
Passenger Seat Cushion
NOTE: Manual seat track shown, power seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat - Exploded View, Front > Page 8072
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat - Exploded View, Front > Page 8073
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat - Exploded View, Front > Page 8074
Power Seat Switch: Service and Repair Memory Set Switch
Memory Set Switch
Removal and Installation
1. Position the gear selector to NEUTRAL.
2. Remove the console trim ring.
3. Open the center console door, remove the 2 screws and pull up on the console finish panel to
release the retainers.
4. Disconnect the power point electrical connector and remove the console finish panel.
5. Pull out to release the retainers and separate the instrument panel center lower RH and LH
finish panels.
6. Pull out to release the retainers and separate the instrument panel center finish panel.
7. Disconnect the electrical connector, release the 4 tabs and remove the memory SET switch.
8. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat - Exploded View, Front > Page 8075
Power Seat Switch: Service and Repair Seat Control Switch
Seat Control Switch
Removal and Installation
All seats
1. Remove the front seat. For additional information, refer to Seat - Front See: Seats/Service and
Repair/Front Seats/Seat - Front.
2. Remove the cushion side shield in the following sequence.
1. Remove the clip and manual recline handle (if equipped).
2. Pull and remove the manual lumbar control knob (if equipped).
3. Remove the scrivet.
4. Remove the retention bracket screw and the retention bracket (if equipped).
5. Release the cushion side shield front clip.
6. From under the cushion side shield, release the 3 hook retainers.
7. Pull out on the cushion side shield at the back and release the pin-type retainer.
8. Separate the cushion trim cover elastic strap from the cushion side shield.
9. 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. For additional information, refer to Seat Front See: Seats/Service and Repair/Front Seats/Seat - Front.
Passenger seat
6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS. For additional information, refer to
General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing
and Inspection/Component Tests and General Diagnostics
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat - Exploded View, Front > Page 8076
Power Seat Switch: Service and Repair Seat Control Switch - Third Row
Seat Control Switch - Third Row
Removal and Installation
NOTE: The third row seat control switches are located in the LH quarter trim panel.
1. Pull out on the third row seat control switch bezel and separate from the LH quarter trim panel.
2. Disconnect the third row seat control switch(es), release the retainers and remove the third row
seat control switch(es).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Sliding Door Switch >
Component Information > Locations
Power Sliding Door Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Sliding Door Switch >
Component Information > Locations > Page 8080
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Sliding Door Switch >
Component Information > Locations > Page 8081
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Sliding Door Switch >
Component Information > Locations > Page 8082
Power Sliding Door Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Sliding Door Switch >
Component Information > Locations > Page 8083
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Page 8087
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Page 8088
Power Trunk / Liftgate Lock Switch: Service and Repair
Liftgate Window Latch Actuator
Removal and Installation
1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See:
Doors, Hood and Trunk/Trunk /
Liftgate/Trunk / Liftgate Latch/Service and Repair/Liftgate Window Latch.
2. Remove the 3 screws and the liftgate window latch actuator.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Locations > Page 8092
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch
Seat Heater Switch: Service and Repair Heated Seat Switch
Heated Seat Switch
Removal and Installation
1. Position the gear selector to NEUTRAL.
2. Remove the console trim ring.
3. Open the center console door, remove the 2 screws and pull up on the console finish panel to
release the retainers.
4. Disconnect the power point electrical connector and remove the console finish panel.
5. Pull out to release the retainers and separate the instrument panel center lower RH and LH
finish panels.
6. Pull out to release the retainers and separate the instrument panel center finish panel.
7. Disconnect the electrical connector, release the 4 tabs and remove the heated seat/heated
windshield switch pack.
8. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 8095
Seat Heater Switch: Service and Repair Seat - Exploded View, Front
Seat - Exploded View, Front
Front Seat Backrest
NOTE: Driver backrest shown, passenger backrest similar.
Driver Seat Cushion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 8096
NOTE: Power seat track shown, manual seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 8097
Passenger Seat Cushion
NOTE: Manual seat track shown, power seat track similar.
NOTE: The retention bracket and screw can be used to repair cushion side shields that will not
retain to the cushion frame wire.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 8098
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 8099
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Locations > Page 8103
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch >
Component Information > Locations > Page 8110
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 Deadeners and Insulators. See: Sound Deadeners and
Insulators 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 NVH characteristics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and
Operation > Insulation > Page 8115
Sound Proofing / Insulation: Description and Operation Sound Deadeners and Insulators
Sound Deadeners and Insulators
WARNING: Always refer to Material Safety Data Sheet (MSDS) when handling chemicals and wear
protective equipment as directed. Examples may include but are not limited to respirators and
chemically resistant gloves. Failure to follow these instructions may result in serious personal
injury.
NOTICE:
- Mastic is made of a combustible material and should be removed prior to carrying out welding
procedures to the area. Heat zones from welding near the mastic may cause the mastic material to
burn.
- Corrosion protection must be restored to the area AFTER the mastic material is applied.
Corrosion protection products may be wax based and loss of adhesion may occur.
NOTE:
- The following illustrations serve as a reference to indicate mastic patch (butyl pad) locations.
Additional insulators and sound deadeners are used beyond those indicated in the illustration.
- To restore the vehicle to design intent, missing or damaged sound deadeners and insulators
should be installed new with the correct service replacement component.
Sound Deadeners and Insulators - Explorer Sport Trac
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and
Operation > Insulation > Page 8116
Sound Deadeners and Insulators - Explorer/Mountaineer
1. NOTE: In applications where mastic material is applied as a pumpable material at the factory,
replacement of missing or damaged mastic is
acceptable in the form of cut-to-fit butyl pad(s) or pumpable mastic material(s) when carrying out
repairs.
Whenever replacement of an existing mastic insulator is carried out, the surface must be
thoroughly cleaned to make sure correct adhesion will occur. The surface should be 10°C (50°F) or
greater before applying the mastic. The use of a heat gun to warm the metal surface will aid in
adhesion.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair >
Tailgate Latch
Tailgate Latch: Service and Repair Tailgate Latch
Tailgate Latch
Removal and Installation
1. Open and support the tailgate.
2. Remove the 7 bolts, the 4 pin-type retainers and the tailgate access panel.
- To install, tighten to 5 Nm (44 lb-in).
3. Open the clip and release the tailgate latch actuating rod from the tailgate remote control.
4. Release the tailgate latch actuating rod locator from the tailgate.
5. Remove the 2 bolts and the tailgate latch.
- To install, tighten to 25 Nm (18 lb-ft).
6. Remove the tailgate latch actuating rod.
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair >
Tailgate Latch > Page 8122
Tailgate Latch: Service and Repair Tailgate Handle, Lock and Latches - Exploded View
Tailgate Handle, Lock and Latches - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair >
Tailgate Latch > Page 8123
Tailgate Latch: Service and Repair Tailgate Latch Remote Control
Tailgate Latch Remote Control
Removal and Installation
1. Open and support the tailgate.
2. Remove the 7 bolts, the 4 pin-type retainers and the tailgate access panel.
- To install, tighten to 5 Nm (44 lb-in).
3. Open the 2 clips and release the 2 tailgate latch actuating rods from the tailgate remote control.
4. Release the 2 tailgate latch actuating rod locators from the tailgate.
5. Remove the 2 nuts and the tailgate remote control.
- To install, tighten to 9 Nm (80 lb-in).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Service and
Repair
Tailgate Lock Cylinder: Service and Repair
Tailgate Lock Cylinder
Removal and Installation
NOTE: When a new lock cylinder is installed, the tailgate lock cylinder, door lock cylinders and the
ignition lock cylinder should be installed as a set. This eliminates carrying an extra key which fits
only 1 lock. If a new key is to be used, the new key code is attached to a tag.
NOTE: The individual door lock cylinders are repaired by discarding the inoperative lock cylinder
and building a new lock cylinder using the appropriate lock repair package. The lock repair
package includes a detailed instruction sheet to build a new lock cylinder to the current key code of
the vehicle.
1. Remove the tailgate release handle. For additional information, refer to Tailgate Release Handle
See: Tailgate Release Handle/Service and
Repair/Tailgate Release Handle.
2. Remove retaining clip and the tailgate lock cylinder.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and
Repair > Tailgate Release Handle
Tailgate Release Handle: Service and Repair Tailgate Release Handle
Tailgate Release Handle
Removal and Installation
1. Remove the tailgate latch remote control. For additional information, refer to Tailgate Latch
Remote Control See: Tailgate Latch/Service and
Repair/Tailgate Latch Remote Control.
2. Remove the tailgate release handle.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and
Repair > Tailgate Release Handle > Page 8131
Tailgate Release Handle: Service and Repair Tailgate Handle, Lock and Latches - Exploded View
Tailgate Handle, Lock and Latches - Exploded View
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and
Repair
Cowl Moulding / Trim: Service and Repair
Cowl Panel Grille
1. Remove the wiper pivot arms.
NOTICE: To avoid breaking the retaining clips on the cowl panel, do not pull up on the rear of the
cowl panel.
2. Pry up on the front of the cowl panel to release it from the retaining clips.
3. Remove the cowl panel grille.
4. Separate the left cowl panel from the right cowl panel by releasing the retaining clips.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component
Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door
Front Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Front Door
Glass, Frames and Mechanisms - Exploded View, Front Door
NOTE: LH shown, RH similar.
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component
Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 8142
Front Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Front
Door Glass Top Run - Front
Removal and Installation
NOTE: For LH front only, the front window motor must be initialized whenever the front window
motor is removed from the window regulator drum housing, a new window regulator is installed, a
new top run is installed or for any operation in which grease or lubricants are applied to the window
regulator or glass run.
1. Remove the front door window glass. For additional information, refer to Window Glass - Front
Door See: Doors, Hood and Trunk/Doors/Front
Door/Front Door Window Glass/Service and Repair/Window Glass - Front Door.
2. Remove the exterior moulding.
3. Remove the front door glass top run channel assembly bolt.
- To install, tighten to 12 Nm (106 lb-in).
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.
- For LH front window only, initialize the LH front window motor. For additional information, refer to
Window Motor Initialization - Front See: Windows and Glass/Windows/Service and Repair/Window
Motor Initialization - Front.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component
Information > Service and Repair > Door Glass Top Run - Rear
Rear Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Rear
Door Glass Top Run - Rear
Removal and Installation
1. Remove the rear door window glass. For additional information, refer to Window Glass - Rear
Door See: Doors, Hood and Trunk/Doors/Rear
Door/Rear Door Window Glass/Service and Repair/Window Glass - Rear Door.
2. Remove the exterior moulding.
3. Remove the rear door glass top run assembly bolt.
- To install, tighten to 12 Nm (106 lb-in).
4. Remove the rear door glass top run channel assembly.
- Remove the rear door glass top run channel assembly through the top opening of the rear door.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component
Information > Service and Repair > Door Glass Top Run - Rear > Page 8147
Rear Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Rear Door
Glass, Frames and Mechanisms - Exploded View, Rear Door
NOTE: Explorer shown, Explorer Sport Trac similar.
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations
Brake Switch (Cruise Control): Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page
8152
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page
8153
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and
Operation > Brake Pedal Position (BPP) Switch
Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch
Engine Control Components
Brake Pedal Position (BPP) Switch
The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal
to the PCM indicating the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Typical BPP Switch
Typical BPP Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and
Operation > Brake Pedal Position (BPP) Switch > Page 8156
Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS)/Brake
Deactivator Switch
Engine Control Components
Brake Pedal Switch (BPS)/Brake Deactivator Switch
The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A
normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is
not applied. When the brake pedal is applied, the normally closed switch opens and power is
removed from the PCM.
On some applications the normally closed BPS, along with the normally open BPP switch, are used
for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be
disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not
changing states when they were expected to, a diagnostic trouble code (DTC) is set by the PCM
strategy.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Description and
Operation
Clutch Switch: Description and Operation
Engine Control Components
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.
Typical Clutch Pedal Position (CPP) Switch
Typical Clutch Pedal Position (CPP) Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair
Cruise Control Switch: Service and Repair
Speed Control Switch
NOTE: Explorer shown, Mountaineer similar.
Removal and Installation
NOTE: It is not necessary to remove the driver air bag module during this procedure.
NOTE: Be careful not to allow the speed control switch electrical connector to fall back into the
steering wheel.
1. Remove the speed control switch by pulling the switch toward the rear of the vehicle.
- Disconnect the electrical connector.
2. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations
Brake Switch (Cruise Control): Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations > Page 8167
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations > Page 8168
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Description and Operation > Brake Pedal Position (BPP) Switch
Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch
Engine Control Components
Brake Pedal Position (BPP) Switch
The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal
to the PCM indicating the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Typical BPP Switch
Typical BPP Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 8171
Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS)/Brake
Deactivator Switch
Engine Control Components
Brake Pedal Switch (BPS)/Brake Deactivator Switch
The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A
normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is
not applied. When the brake pedal is applied, the normally closed switch opens and power is
removed from the PCM.
On some applications the normally closed BPS, along with the normally open BPP switch, are used
for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be
disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not
changing states when they were expected to, a diagnostic trouble code (DTC) is set by the PCM
strategy.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Description and Operation
Clutch Switch: Description and Operation
Engine Control Components
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.
Typical Clutch Pedal Position (CPP) Switch
Typical Clutch Pedal Position (CPP) Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Service and Repair
Cruise Control Switch: Service and Repair
Speed Control Switch
NOTE: Explorer shown, Mountaineer similar.
Removal and Installation
NOTE: It is not necessary to remove the driver air bag module during this procedure.
NOTE: Be careful not to allow the speed control switch electrical connector to fall back into the
steering wheel.
1. Remove the speed control switch by pulling the switch toward the rear of the vehicle.
- Disconnect the electrical connector.
2. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component
Information > Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component
Information > Diagrams > Page 8182
Air Bag Deactivation Indicator: Service and Repair
Passenger Air Bag Deactivation (PAD) Indicator
Removal and Installation
1. NOTE: Ignition must be OFF if disconnecting the Passenger Air Bag Deactivation (PAD)
indicator electrical connector. Otherwise, a DTC will be
set in the Restraints Control Module (RCM) memory and must be cleared before releasing the
vehicle.
Turn the ignition OFF and wait at least one minute.
2. Remove the floor console.
3. Gently pull outward to release the clips on the instrument panel center finish panel.
4. Disconnect the PAD indicator electrical connector.
5. Remove the 2 screws and PAD indicator.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions
Cigarette Lighter: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8187
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8188
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8189
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8190
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
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8191
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery 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 loose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8192
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8193
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8194
Symbols (Part 4)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8195
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8196
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.
Defective insulation stripping
1 = Proper crimp
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8197
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8198
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8199
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8200
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8201
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.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8202
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 (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8203
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8204
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8205
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 (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8206
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 (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Service and Repair > Compass Zone Adjustment
Compass: Service and Repair Compass Zone Adjustment
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 - Early Build
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 (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Service and Repair > Compass Zone Adjustment > Page 8212
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.
Without Message Center - Late Build
1. Turn the ignition switch to the ON position.
2. Determine which magnetic zone you are in for your geographic location.
3. Press and release the SELECT/RESET button until HOLD RESET FOR SYSTEM CHECK is
displayed in the integrated circuit display.
4. Quickly release the SELECT/RESET button.
5. Press and release the SELECT/RESET button to scroll through the setup menu until COMPASS
ZONE XX is displayed in the integrated circuit
display.
6. Press and hold the SELECT/RESET button for approximately 2 seconds to enter the compass
zone setting mode.
7. Press and release the SELECT/RESET button until the correct zone setting for your geographic
location appears in the integrated circuit display.
8. Release the SELECT/RESET button and allow the setup timer to expire to exit the procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Service and Repair > Compass Zone Adjustment > Page 8213
Compass: Service and Repair Compass Calibration
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 takes up to 5 circles to complete the calibration.
NOTE: 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 - Early Build
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 until
CIRCLE SLOWLY TO CALIBRATE is displayed and
release.
4. NOTE: It takes up to 5 circles to complete the calibration.
NOTE: 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 (IC) display.
Without Message Center - Late Build
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. Press and release the SELECT/RESET button to scroll through the information menu until HOLD
RESET FOR SYSTEM CHECK is displayed.
3. Quickly release the SELECT/RESET button.
4. Press and release the SELECT/RESET button to scroll through the setup menu until COMPASS
ZONE XX is displayed in the integrated circuit
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Service and Repair > Compass Zone Adjustment > Page 8214
display.
5. Press and hold the SELECT/RESET button for approximately 2 seconds to enter the compass
zone setting mode.
6. Release the SELECT/RESET button.
7. Press and hold the SELECT/RESET button until CIRCLE SLOWLY TO CALIBRATE appears in
the integrated display.
8. NOTE: It can take up to 5 circles to complete the calibration.
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 IC display.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Depowering Procedure
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
may result in serious personal injury.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
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(R) and
cause serious personal injury or death.
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (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 RCM fuse 17 (10A) from the SJB.
For additional information, refer to the Wiring Diagram.
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 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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8220
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 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 an 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 (V6-4.0L (2009))
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 8221
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Deactivation and Reactivation
Supplemental Restraint System (SRS) Deactivation and Reactivation
Deactivation
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
may result in serious personal injury.
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.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
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.
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
All vehicles
1. Turn all vehicle accessories OFF.
2. Turn the ignition switch OFF.
3. At the Smart Junction Box (SJB), located below the LH side of the instrument panel, remove the
cover and RCM fuse 17 (10A) from the SJB. For
additional information, refer to the Wiring Diagrams.
4. Turn the ignition switch 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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8222
7. Remove the 2 driver air bag module bolts (1 shown).
8. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag
module.
9. Open and lower the glove compartment door.
10. Detach the wiring retainer, remove the 4 bolts and passenger air bag module heat shield.
11. NOTE: The canister vent and adaptive tether do not require deactivation.
Disconnect the LH side passenger air bag module electrical connector.
12. Under the rear of the passenger seat, detach the passenger seat side air bag module electrical
connector from the seat track bracket. Disengage the
passenger seat side air bag module electrical connector locking clip, release the tab and
disconnect the passenger seat side air bag module electrical connector.
Explorer and Mountaineer vehicles
13. Release and position aside the passenger side C-pillar trim panel.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8223
14. Disconnect the passenger side safety canopy module electrical connector.
15. Release and position aside the driver side C-pillar trim panel.
16. Disconnect the driver side safety canopy module electrical connector.
Explorer Sport Trac vehicles
17. Remove the driver and passenger side upper C-pillar trim panels.
18. Disconnect the passenger side safety canopy module electrical connector.
19. Disconnect the driver side safety canopy module electrical connector.
All vehicles
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8224
20. Under driver seat, the rear of the slide and disengage the driver seat side air bag module
electrical connector locking clip, release the tab and
disconnect the driver seat side air bag module electrical connector.
21. Install the RCM fuse 17 (10A) to the SJB.
22. 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. Connect the driver seat side air bag module electrical connector and engage the seat side air
bag electrical connector locking clip.
Explorer Sport Trac vehicles
4. Connect the driver side safety canopy module electrical connector.
5. Connect the passenger side safety canopy module electrical connector.
6. Install the driver and passenger upper C-pillar trim panels.
Explorer and Mountaineer vehicles
7. Connect the driver side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8225
8. Install the driver side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
9. Connect the passenger side safety canopy module electrical connector.
10. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles
11. Connect the passenger seat side air bag module electrical connector and engage the seat side
air bag electrical connector locking clip. Attach the
passenger seat side air bag module electrical connector to the seat track bracket.
12. Connect the LH side passenger air bag module electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8226
13. Install the passenger air bag module heat shield and 4 bolts. Attach the wiring retainer.
14. NOTICE: 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.
15. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
16. Turn the ignition switch from OFF to ON.
17. Install RCM fuse 17 (10A) to the SJB and install the cover.
18. 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.
19. 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 an 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 (V6-4.0L (2009))
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
Removal and Installation
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.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Door Ajar Switch, Driver Side Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Door Ajar Switch, Driver Side Front > Page 8234
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Door Ajar Switch, Driver Side Front > Page 8235
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Door Ajar Switch, Driver Side Front > Page 8236
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Door Ajar Switch, Driver Side Front > Page 8237
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Glass Ajar Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Glass Ajar Switch > Page 8240
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Glass Ajar Switch > Page 8241
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Glass Ajar Switch > Page 8242
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Glass Ajar Switch > Page 8243
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal and Installation
1. Remove the front door latch. For additional information, refer to Front Door Latch See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Front Door Latch/Service and Repair/Removal and Replacement/Front Door Latch.
2. Disconnect the front door ajar switch electrical connector.
3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the
switch from the front door latch.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Service and Repair > Door Ajar Switch - Front Door > Page 8246
Door Switch: Service and Repair Door Ajar Switch - Liftgate
Door Ajar Switch - Liftgate
Removal and Installation
1. Remove the liftgate latch. For additional information, refer to Liftgate Latch See: Body and
Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk
/ Liftgate Latch/Service and Repair/Liftgate Latch.
2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar
switch form the liftgate latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Service and Repair > Door Ajar Switch - Front Door > Page 8247
Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass
Door Ajar Switch - Liftgate Glass
Removal and Installation
1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See:
Body and Frame/Doors, Hood and
Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/Liftgate Window Latch.
2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the
liftgate window latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Service and Repair > Door Ajar Switch - Front Door > Page 8248
Door Switch: Service and Repair Door Ajar Switch - Rear Door
Door Ajar Switch - Rear Door
Removal and Installation
1. Remove the rear door latch. For additional information, refer to Rear Door Latch See: Body and
Frame/Doors, Hood and Trunk/Doors/Rear
Door/Rear Door Latch/Service and Repair/Removal and Replacement/Rear Door Latch.
2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch
from the rear door latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations > Page 8252
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Service and Repair > Reset Procedure
Driver/Vehicle Information Display: Reset Procedure
Message Center Configuration
Oil Life Reset And Start Value - With Message Center
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 - Without Message Center
NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180
days.
NOTE: All message center functions are carried out using the single stem reset button in the
Instrument Cluster (IC).
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 (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Service and Repair > Reset Procedure > Page 8255
Driver/Vehicle Information Display: Removal and Replacement
Message Center Switch
Removal and Installation
1. Remove the instrument panel center finish panel.
2. Press the retaining tabs and remove the message center switch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 >
Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Fuel Distance/Mileage Module: Customer Interest Instruments - Trip Odometers/Fuel Economy
Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8264
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module: >
09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Fuel Distance/Mileage Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel
Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8270
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
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 is detected by the inability to pull vacuum in the fuel tank after a fueling event.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams
Fuel Gauge Sender: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Fuel Pump (FP) Module
Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module
Engine Control Components
Fuel Pump (FP) Module
The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is
located inside the FP module reservoir and supplies fuel through the FP module manifold to the
engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a
check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Mechanical Returnless Fuel Pump (FP) Module
Typical Mechanical Returnless Fuel Pump (FP) Module
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Fuel Pump (FP) Module > Page 8279
Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module and Reservoir
Engine Control Components
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 ignition has been turned off to minimize starting
concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low
tank fill levels.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Page 8280
Fuel Gauge Sender: Service and Repair
Fuel Tank and Filler Pipe - Exploded View
Explorer Sport Trac
NOTE: Vehicle body removed from art for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Page 8281
Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Page 8282
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Page 8283
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Depowering Procedure
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
may result in serious personal injury.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
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(R) and
cause serious personal injury or death.
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (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 RCM fuse 17 (10A) from the SJB.
For additional information, refer to the Wiring Diagram.
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 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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8289
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 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 an 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 (V6-4.0L (2009))
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 8290
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Deactivation and Reactivation
Supplemental Restraint System (SRS) Deactivation and Reactivation
Deactivation
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
may result in serious personal injury.
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.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) 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.
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.
WARNING: 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 correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
All vehicles
1. Turn all vehicle accessories OFF.
2. Turn the ignition switch OFF.
3. At the Smart Junction Box (SJB), located below the LH side of the instrument panel, remove the
cover and RCM fuse 17 (10A) from the SJB. For
additional information, refer to the Wiring Diagrams.
4. Turn the ignition switch 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 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8291
7. Remove the 2 driver air bag module bolts (1 shown).
8. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag
module.
9. Open and lower the glove compartment door.
10. Detach the wiring retainer, remove the 4 bolts and passenger air bag module heat shield.
11. NOTE: The canister vent and adaptive tether do not require deactivation.
Disconnect the LH side passenger air bag module electrical connector.
12. Under the rear of the passenger seat, detach the passenger seat side air bag module electrical
connector from the seat track bracket. Disengage the
passenger seat side air bag module electrical connector locking clip, release the tab and
disconnect the passenger seat side air bag module electrical connector.
Explorer and Mountaineer vehicles
13. Release and position aside the passenger side C-pillar trim panel.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8292
14. Disconnect the passenger side safety canopy module electrical connector.
15. Release and position aside the driver side C-pillar trim panel.
16. Disconnect the driver side safety canopy module electrical connector.
Explorer Sport Trac vehicles
17. Remove the driver and passenger side upper C-pillar trim panels.
18. Disconnect the passenger side safety canopy module electrical connector.
19. Disconnect the driver side safety canopy module electrical connector.
All vehicles
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8293
20. Under driver seat, the rear of the slide and disengage the driver seat side air bag module
electrical connector locking clip, release the tab and
disconnect the driver seat side air bag module electrical connector.
21. Install the RCM fuse 17 (10A) to the SJB.
22. 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. Connect the driver seat side air bag module electrical connector and engage the seat side air
bag electrical connector locking clip.
Explorer Sport Trac vehicles
4. Connect the driver side safety canopy module electrical connector.
5. Connect the passenger side safety canopy module electrical connector.
6. Install the driver and passenger upper C-pillar trim panels.
Explorer and Mountaineer vehicles
7. Connect the driver side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8294
8. Install the driver side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
9. Connect the passenger side safety canopy module electrical connector.
10. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles
11. Connect the passenger seat side air bag module electrical connector and engage the seat side
air bag electrical connector locking clip. Attach the
passenger seat side air bag module electrical connector to the seat track bracket.
12. Connect the LH side passenger air bag module electrical connector.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8295
13. Install the passenger air bag module heat shield and 4 bolts. Attach the wiring retainer.
14. NOTICE: 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.
15. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
16. Turn the ignition switch from OFF to ON.
17. Install RCM fuse 17 (10A) to the SJB and install the cover.
18. 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.
19. 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 an 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 (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Bulb > Component Information > Service and Repair
Instrument Panel Bulb: Service and Repair
Instrument Cluster Bulb
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 (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 8307
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 8313
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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: > 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 (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator >
Component Information > Service and Repair > Oil Life Reset and Start Value - With Message Center
Maintenance Required Lamp/Indicator: Service and Repair Oil Life Reset and Start Value - With
Message Center
Message Center Configuration
Oil Life Reset And Start Value - With Message Center
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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator >
Component Information > Service and Repair > Oil Life Reset and Start Value - With Message Center > Page 8328
Maintenance Required Lamp/Indicator: Service and Repair Oil Life Reset and Start Value - Without
Message Center
Message Center Configuration
Oil Life Reset And Start Value - Without Message Center
NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180
days.
NOTE: All message center functions are carried out using the single stem reset button in the
Instrument Cluster (IC).
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 (V6-4.0L (2009))
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)
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 four 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 three
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/No Diagnostic
Trouble Codes (DTCs) Present Symptom Chart Index.
- 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 ignition in the RUN position (engine not running) if
DTC P1000 is set.
CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Customer Interest for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display
Moves On Screen
Odometer: Customer Interest Instruments - Odometer Display Moves On Screen
TSB 10-2-15
02/15/10
ODOMETER DISPLAY READING MOMENTARILY FLIPS FROM BOTTOM TO TOP OF
MESSAGE CENTER SCREEN
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit a condition where the odometer display reading momentarily flips from the bottom to the top
of the message center screen, then back to the normal display mode (Figure 1). This concern may
be very intermittent and difficult to verify.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
The following procedure involves installing a Fair Rite Round Cable Snap-On Suppressor (only one
required) which must be ordered directly from the supplier Newark listed below:
^ Newark telephone number 1-800-463-9275.
^ Newark website: www.Newark.com.
^ Newark part number: 78K6137.
^ Manufacturer: Fair Rite.
^ Manufacturer part number: 0444176451.
1. Remove the Instrument Cluster (IC). Refer to the Workshop Manual (WSM), Section 413-01.
NOTE
IT IS NOT NECESSARY TO DOWNLOAD THE IC CONFIGURATION INFORMATION.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Customer Interest for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display
Moves On Screen > Page 8340
2. Install the Fair Rite Round Cable Snap-On Suppressor around the cluster harness circuits.
(Figure 3)
3. Install PVC tape (164-R4901) from Rotunda kit (164-R4900) around the suppressor. (Figure 4)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Customer Interest for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display
Moves On Screen > Page 8341
4. Install a tie strap in between the Suppressor and the wiring harness. (Figure 5)
5. Tuck the suppressor behind the IC plastic support bracket and secure the tie strap around the
instrument cluster bracket. (Figure 6)
6. Install the IC. Refer to WSM, Section 413-01.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
100215A 2006-2010 Explorer, 0.7 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Install
Suppressor, Includes Time To Remove And Install The Instrument Cluster (Do Not Use With Any
Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Customer Interest for Odometer: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel
Economy Resets
Odometer: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Customer Interest for Odometer: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel
Economy Resets > Page 8346
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer
Display Moves On Screen
Odometer: All Technical Service Bulletins Instruments - Odometer Display Moves On Screen
TSB 10-2-15
02/15/10
ODOMETER DISPLAY READING MOMENTARILY FLIPS FROM BOTTOM TO TOP OF
MESSAGE CENTER SCREEN
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit a condition where the odometer display reading momentarily flips from the bottom to the top
of the message center screen, then back to the normal display mode (Figure 1). This concern may
be very intermittent and difficult to verify.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
The following procedure involves installing a Fair Rite Round Cable Snap-On Suppressor (only one
required) which must be ordered directly from the supplier Newark listed below:
^ Newark telephone number 1-800-463-9275.
^ Newark website: www.Newark.com.
^ Newark part number: 78K6137.
^ Manufacturer: Fair Rite.
^ Manufacturer part number: 0444176451.
1. Remove the Instrument Cluster (IC). Refer to the Workshop Manual (WSM), Section 413-01.
NOTE
IT IS NOT NECESSARY TO DOWNLOAD THE IC CONFIGURATION INFORMATION.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer
Display Moves On Screen > Page 8352
2. Install the Fair Rite Round Cable Snap-On Suppressor around the cluster harness circuits.
(Figure 3)
3. Install PVC tape (164-R4901) from Rotunda kit (164-R4900) around the suppressor. (Figure 4)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer
Display Moves On Screen > Page 8353
4. Install a tie strap in between the Suppressor and the wiring harness. (Figure 5)
5. Tuck the suppressor behind the IC plastic support bracket and secure the tie strap around the
instrument cluster bracket. (Figure 6)
6. Install the IC. Refer to WSM, Section 413-01.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
100215A 2006-2010 Explorer, 0.7 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Install
Suppressor, Includes Time To Remove And Install The Instrument Cluster (Do Not Use With Any
Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 09-21-7 > Nov > 09 > Instruments - Trip
Odometers/Fuel Economy Resets
Odometer: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 09-21-7 > Nov > 09 > Instruments - Trip
Odometers/Fuel Economy Resets > Page 8358
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations
Oil Pressure Sender: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations > Page 8365
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations > Page 8366
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator >
Component Information > Diagrams
Parking Assist Warning Indicator: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator >
Component Information > Diagrams > Page 8370
Parking Assist Warning Indicator: Service and Repair
Parking Aid Speaker
Removal and Installation
1. Remove the LH C-pillar trim panel.
2. Remove the bolt and the speaker and bracket assembly.
- Disconnect the electrical connector.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Locations
Parking Brake Warning Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Locations > Page 8374
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Locations > Page 8375
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel
Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Fuel Distance/Mileage Module: Customer Interest Instruments - Trip Odometers/Fuel Economy
Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8385
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Fuel Distance/Mileage Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel
Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8391
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument
Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Instrument Panel Control Module: Customer Interest Instruments - Trip Odometers/Fuel Economy
Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8400
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Instrument Panel Control Module: All Technical Service Bulletins Instruments - Trip
Odometers/Fuel Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
8406
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 System
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, 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.
When replacing any active occupant restraint components, use only the replacement parts
specified in the Ford Customer Service Division Master Parts and Accessories Catalog.
Safety Belt Warning System
The safety belt warning system is a reminder to fasten the driver safety belt. Refer to Diagnosis
and Testing, Safety Belt System See: Restraint Systems/Seat Belt Systems/Testing and
Inspection/Component Tests and General Diagnostics.
Belt-Minder(R)
The Belt-Minder(R) feature is a supplemental warning to the safety belt warning function. This
feature provides additional reminders to the driver that the driver safety belt is unbuckled. Refer to
Diagnosis and Testing, Safety Belt System See: Restraint Systems/Seat Belt Systems/Testing and
Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component
Information > Description and Operation > Page 8410
Seat Belt Reminder Buzzer: Service and Repair
Belt-Minder(R) Deactivating/Activating
Preparation
NOTE: The Belt-Minder(R) Deactivating/Activating procedure can also be carried out using the
scan tool.
1. Apply the parking brake before deactivating/activating the Belt-Minder(R).
2. Place the gear selector lever in PARK (P).
3. Place the ignition switch in the OFF position.
4. Close all the vehicle doors.
5. Unbuckle the driver and the front passenger safety belts.
Deactivating/Activating
1. Turn the ignition switch to the ON position (do not start the engine).
2. Wait until the safety belt warning indicator turns off (approximately 1 minute).
3. NOTE: Step 3 must be completed within 50 seconds after the safety belt warning indicator turns
off.
For the seating position being disabled, at a moderate speed, buckle then unbuckle the safety belt
9 times, ending with the safety belt in the unbuckled state. After this step the safety belt warning
indicator illuminates for 3 seconds.
4. Within 5 seconds after the safety belt warning indicator turns off, at a moderate speed, buckle
then unbuckle the safety belt.
- This disables the Belt-Minder(R) feature for that seating position, if it is currently enabled. As
confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds.
- This enables the Belt-Minder(R) feature for that seating position, if it is currently disabled. As
confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds followed by
a second flash sequence after a brief pause.
5. After confirmation, the deactivation/activation procedure is complete.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 System
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, 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.
When replacing any active occupant restraint components, use only the replacement parts
specified in the Ford Customer Service Division Master Parts and Accessories Catalog.
Safety Belt Warning System
The safety belt warning system is a reminder to fasten the driver safety belt. Refer to Diagnosis
and Testing, Safety Belt System See: Restraint Systems/Seat Belt Systems/Testing and
Inspection/Component Tests and General Diagnostics.
Belt-Minder(R)
The Belt-Minder(R) feature is a supplemental warning to the safety belt warning function. This
feature provides additional reminders to the driver that the driver safety belt is unbuckled. Refer to
Diagnosis and Testing, Safety Belt System See: Restraint Systems/Seat Belt Systems/Testing and
Inspection/Component Tests and General Diagnostics.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component
Information > Description and Operation > Page 8414
Seat Belt Reminder Lamp: Service and Repair
Belt-Minder(R) Deactivating/Activating
Preparation
NOTE: The Belt-Minder(R) Deactivating/Activating procedure can also be carried out using the
scan tool.
1. Apply the parking brake before deactivating/activating the Belt-Minder(R).
2. Place the gear selector lever in PARK (P).
3. Place the ignition switch in the OFF position.
4. Close all the vehicle doors.
5. Unbuckle the driver and the front passenger safety belts.
Deactivating/Activating
1. Turn the ignition switch to the ON position (do not start the engine).
2. Wait until the safety belt warning indicator turns off (approximately 1 minute).
3. NOTE: Step 3 must be completed within 50 seconds after the safety belt warning indicator turns
off.
For the seating position being disabled, at a moderate speed, buckle then unbuckle the safety belt
9 times, ending with the safety belt in the unbuckled state. After this step the safety belt warning
indicator illuminates for 3 seconds.
4. Within 5 seconds after the safety belt warning indicator turns off, at a moderate speed, buckle
then unbuckle the safety belt.
- This disables the Belt-Minder(R) feature for that seating position, if it is currently enabled. As
confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds.
- This enables the Belt-Minder(R) feature for that seating position, if it is currently disabled. As
confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds followed by
a second flash sequence after a brief pause.
5. After confirmation, the deactivation/activation procedure is complete.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal and Installation
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.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 8423
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 8424
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 8425
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 8426
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8429
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8430
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8431
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8432
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal and Installation
1. Remove the front door latch. For additional information, refer to Front Door Latch See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Front Door Latch/Service and Repair/Removal and Replacement/Front Door Latch.
2. Disconnect the front door ajar switch electrical connector.
3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the
switch from the front door latch.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8435
Door Switch: Service and Repair Door Ajar Switch - Liftgate
Door Ajar Switch - Liftgate
Removal and Installation
1. Remove the liftgate latch. For additional information, refer to Liftgate Latch See: Body and
Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk
/ Liftgate Latch/Service and Repair/Liftgate Latch.
2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar
switch form the liftgate latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8436
Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass
Door Ajar Switch - Liftgate Glass
Removal and Installation
1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See:
Body and Frame/Doors, Hood and
Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/Liftgate Window Latch.
2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the
liftgate window latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8437
Door Switch: Service and Repair Door Ajar Switch - Rear Door
Door Ajar Switch - Rear Door
Removal and Installation
1. Remove the rear door latch. For additional information, refer to Rear Door Latch See: Body and
Frame/Doors, Hood and Trunk/Doors/Rear
Door/Rear Door Latch/Service and Repair/Removal and Replacement/Rear Door Latch.
2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch
from the rear door latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Diagrams
Fuel Gauge Sender: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module
Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module
Engine Control Components
Fuel Pump (FP) Module
The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is
located inside the FP module reservoir and supplies fuel through the FP module manifold to the
engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a
check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Mechanical Returnless Fuel Pump (FP) Module
Typical Mechanical Returnless Fuel Pump (FP) Module
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 8443
Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module and Reservoir
Engine Control Components
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 ignition has been turned off to minimize starting
concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low
tank fill levels.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Page 8444
Fuel Gauge Sender: Service and Repair
Fuel Tank and Filler Pipe - Exploded View
Explorer Sport Trac
NOTE: Vehicle body removed from art for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Page 8445
Explorer/Mountaineer
NOTE: Vehicle body removed for clarity.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Page 8446
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Page 8447
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Parking Brake Warning Switch > Component Information > Locations > Page 8451
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Parking Brake Warning Switch > Component Information > Locations > Page 8452
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 See: Testing and
Inspection/Programming and Relearning.
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire
Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and
appliance operation, cellular telephones, remote transmitters, power inverters and portable
entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to
activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not
respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate
the same sensor again.
NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not
recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and
the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire
procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for
front and rear tires, tire rotation will not affect the system.
1. Turn the ignition switch to the OFF position, then press and release the brake pedal.
2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
3. Press and release the brake pedal.
4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
- The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully. If equipped, the message center will display TRAIN LF TIRE.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in
place 180 degrees from the valve stem.
Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from
the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The
horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8458
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall opposite (180 degrees) from the
valve stem and press and release the test button to train the RF tire pressure sensor.
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 identifiers 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 carry out
the SJB On-Demand Self Test.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8459
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 Tire Pressure Monitor 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 Tire Pressure Monitor 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. See: Testing and Inspection/Symptom Related Diagnostic
Procedures
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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. NOTICE: 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. For additional information, refer to Wheel and Tire See:
Maintenance/Wheels and Tires/Service and Repair/Overhaul.
2. NOTICE: 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.
3. NOTICE: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8462
4. Remove the sensor.
Assembly
1. NOTICE: 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.
3. NOTICE: 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. For additional information, refer to Wheel and Tire See:
Maintenance/Wheels and Tires/Service and Repair/Overhaul.
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 See: Testing and Inspection/Monitors, Trips, Drive Cycles and
Readiness Codes.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8463
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
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 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 See: 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8464
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 in) 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. NOTICE: 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.
Using wheel and tire cleaner, clean the area where the sensor and cradle are to be installed.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8465
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. NOTICE: 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 in) away from the sensor and tighten the worm gear.
- Tighten to 3 Nm (27 lb-in).
6. NOTICE: 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. For additional information, refer to Wheel and Tire. See:
Maintenance/Wheels and Tires/Service and Repair/Overhaul
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. See: Testing and Inspection/Monitors, Trips, Drive Cycles and
Readiness Codes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Engine Control Components
Transmission Control Indicator Lamp (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 8473
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 8474
Ambient Light Sensor: Service and Repair
Light Sensor
Removal and Installation
1. Position the top portion of the lower center instrument panel finish panel rearward.
2. Remove the upper center instrument panel finish panel.
- Disconnect the electrical connector.
3. Remove the 2 screws and the light sensor.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations
Backup Lamp Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations > Page 8479
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations > Page 8480
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Brake Lamp: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8485
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8486
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8487
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8488
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
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8489
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery 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 loose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8490
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8491
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8492
Symbols (Part 4)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8493
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8494
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.
Defective insulation stripping
1 = Proper crimp
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8495
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8496
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8497
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8498
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8499
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.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8500
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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8501
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8502
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8503
Brake Lamp: Connector Views
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8504
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8505
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8506
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8507
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8508
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 (V6-4.0L (2009))
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and Instructions > Page 8509
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 (V6-4.0L (2009))
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
Special Tools Used With Diagnostics
Stoplamps
Principles Of Operation
Stoplamps
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
The SJB utilizes a Field-Effect Transistor (FET) protective circuit strategy for many of its outputs
(for example, a 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 event is detected. A continuous DTC is stored at the fault event and a
cumulative counter is started.
When the demand for the output is no longer present, the module resets the FET circuit protection
to allow the circuit to function. The next time the driver requests a circuit to activate that has been
shut down by a previous short (FET protection) and the circuit remains shorted, the FET protection
shuts off the circuit again and the cumulative counter advances.
When the excessive circuit load occurs often enough, the module shuts down the output until a
repair procedure is carried out. Each FET protected circuit has 3 predefined levels of short circuit
tolerance based on the harmful effect of each circuit fault on the FET and the ability of the FET to
withstand it. A module lifetime level of fault events is established based upon the durability of the
FET. If the total tolerance level is determined to be 600 fault events, the 3 predefined levels would
be 200, 400 and 600 fault events.
When each tolerance level is reached, 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 operation until a successful self-test proves that
the fault has been repaired. After the self-test has successfully completed (no on-demand DTCs
present), the continuous DTC automatically clears and the circuit function returns.
When the first or second level is reached, the continuous DTC (associated with the short circuit)
sets along with DTC B106E. These DTCs can be cleared using the module on-demand self-test,
then the Clear DTC operation on the scan tool (if the on-demand test shows the fault corrected).
The module never resets the fault event counter to zero and continues to advance the fault event
counter as short circuit fault events occur.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8512
If the number of short circuit fault events reach the third level, then DTCs B106F and B1342 set
along with the associated continuous DTC. This DTC cannot be cleared and the module must be
replaced.
Inspection And Verification
Stoplamps
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.
NOTE: Make sure the multifunction switch is in the LOW BEAM position.
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, No Power To The Scan Tool, to diagnose no power to 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 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.
- 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 Diagnostic Trouble Code (DTC) Chart
See: Testing and Inspection. For all other DTCs,
refer to the Diagnostic Trouble Code (DTC) Chart in Body Control Systems. See: Body and
Frame/Body Control Systems/Testing and Inspection/Diagnostic Trouble Code
Descriptions/Diagnostic Trouble Code (DTC) Chart
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8513
Brake Lamp: Symptom Related Diagnostic Procedures
Stoplamps
Symptom Chart
Symptom Chart
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8514
Brake Lamp: Pinpoint Tests
Pinpoint Test I: One Or More Stoplamps Are Inoperative
Stoplamps
Pinpoint Tests
Pinpoint Test I: One Or More Stoplamps Are Inoperative
Refer to Wiring Diagram Set 90, Turn Signal/Stop/Hazard Lamps for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
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). 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). 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).
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).
B2048-B2051 / C1788
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- High mounted stoplamp
- LED module
- SJB
PINPOINT TEST I: ONE OR MORE STOPLAMPS ARE INOPERATIVE
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8515
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- I1 CHECK THE RECORDED DTCs FROM THE SJB
SELF-TEST
- Check the recorded results from the SJB self-test.
- Is DTC C1788, B2048 or B2050 recorded?
Yes
For DTC C1788, GO to I2.
For DTC B2048 or B2050, GO to I5.
No
GO to I7.
------------------------------------------------- I2 CHECK THE LH LED MODULE FOR A SHORT TO
GROUND
- Disconnect: LH Rear Lamp C419.
- Ignition ON.
- Enter the following diagnostic mode on the scan tool: SJB Self-Test.
- Clear the DTCs and repeat the SJB on-demand self-test.
- Is DTC C1788 still present?
Yes
GO to I3.
No
INSTALL a new LED module. RUN the on-demand self-test (required to clear certain DTCs).
CORRECT any unresolved DTCs. CLEAR all DTCs. TEST the system for normal operation.
------------------------------------------------- I3 CHECK THE RH LED MODULE FOR A SHORT TO
GROUND
- Disconnect: RH Rear Lamp C418.
- Enter the following diagnostic mode on the scan tool: SJB Self-Test.
- Clear the DTCs and repeat the SJB on-demand self-test.
- Is DTC C1788 still present?
Yes
GO to I4.
No
INSTALL a new LED module. RUN the on-demand self-test (required to clear certain DTCs).
CORRECT any unresolved DTCs. CLEAR all DTCs. TEST the system for normal operation.
------------------------------------------------- I4 CHECK CIRCUIT CLS44 (VT/BN) FOR A SHORT TO
GROUND
- Ignition OFF.
- Disconnect: SJB C2280a.
- Measure the resistance between the LH rear lamp C419-1, circuit CLS44 (VT/BN), harness side
and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8516
- Is the resistance greater than 10,000 ohms?
Yes
GO to I15.
No
VERIFY the SJB fuse 27 (15A) is OK. If OK, REPAIR the circuit. RUN the on-demand self-test
(required to clear certain DTCs). CORRECT any unresolved DTCs. CLEAR all DTCs. TEST the
system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible
causes of the circuit short.
------------------------------------------------- I5 CHECK THE BULB HOLDER FOR A SHORT TO
GROUND
- Disconnect: Inoperative Stoplamp.
- Ignition ON.
- Enter the following diagnostic mode on the scan tool: SJB Self-Test.
- Clear the DTCs and repeat the SJB on-demand self-test.
- Is DTC B2048 or B2050 still present?
Yes
GO to I6.
No
INSTALL a new bulb holder in question. TEST the system for normal operation.
------------------------------------------------- I6 CHECK CIRCUIT CLS18 (GY/BN) OR CLS19 (VT/OG)
FOR A SHORT TO GROUND
- Ignition OFF.
- Disconnect: SJB C2280a.
- For Explorer, measure the resistance between the inoperative rear lamp, harness side and
ground as follows:
- For Explorer Sport Trac, measure the resistance between the inoperative rear lamp, harness side
and ground as follows:
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8517
- Is the resistance greater than 10,000 ohms?
Yes
GO to I15.
No
VERIFY the SJB fuse 22 (15A) is OK. If OK, REPAIR the circuit in question. RUN the on-demand
self-test (required to clear certain DTCs). CORRECT any unresolved DTCs. CLEAR all DTCs.
TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the
possible causes of the circuit short.
------------------------------------------------- I7 DETERMINE THE INOPERATIVE STOPLAMP
- Ignition OFF.
- Apply the brake pedal.
- Verify the high mounted stoplamp operation.
- Is the high mounted stoplamp illuminated?
Yes
If one rear stoplamp is inoperative, GO to I11.
For Mountaineer, if both rear stoplamps are inoperative, GO to I13.
For Explorer Sport Trac, if both rear stoplamps are inoperative, GO to I14.
For Explorer, if both rear stoplamps are inoperative, GO to I15.
No
GO to I8.
------------------------------------------------- I8 CHECK CIRCUIT CCB08 (VT/WH) FOR VOLTAGE
- For Explorer or Mountaineer, while applying the brake pedal, measure the voltage between the
high mounted stoplamp C475-1, circuit CCB08 (VT/WH), harness side and ground.
- For Explorer Sport Trac, while applying the brake pedal, measure the voltage between the high
mounted stoplamp C927-3, circuit CCB08 (VT/WH), harness side and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8518
- Is the voltage greater than 10 volts?
Yes
GO to I9.
No
GO to I10.
------------------------------------------------- I9 CHECK THE HIGH MOUNTED STOPLAMP GROUND
CIRCUIT FOR AN OPEN
- Disconnect: Negative Battery Cable.
- Disconnect: High Mounted Stoplamp C475 (Explorer, Mountaineer) or C927 (Explorer Sport
Trac).
- For Explorer or Mountaineer, measure the resistance between the high mounted stoplamp
C475-2, circuit GD149 (BK/GY), harness side and ground.
- For Explorer Sport Trac, measure the resistance between the high mounted stoplamp C927-1,
circuit GD133 (BK), harness side and ground.
- Is the resistance less than 5 ohms?
Yes
INSTALL a new high mounted stoplamp. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- I10 CHECK CIRCUIT CCB08 (VT/WH) FOR AN OPEN
- Disconnect: SJB C2280a.
- For Explorer or Mountaineer, measure the resistance between the high mounted stoplamp
C475-1, circuit CCB08 (VT/WH), harness side and the SJB C2280a-15, circuit CCB08 (VT/WH),
harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8519
- For Explorer Sport Trac, measure the resistance between the high mounted stoplamp C927-3,
circuit CCB08 (VT/WH), harness side and the SJB C2280a-15, circuit CCB08 (VT/WH), harness
side.
- Is the resistance less than 5 ohms?
Yes
GO to I15.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- I11 CHECK THE REAR LAMP GROUND CIRCUIT FOR AN
OPEN
- Place the headlamp switch in the PARKING LAMPS ON position.
- Does the rear lamp in question illuminate?
Yes
For Mountaineer, TURN the parking lamps off. GO to I12.
For Explorer or Explorer Sport Trac, TURN the parking lamps off. GO to I13.
No
REPAIR the ground circuit in question for an open. CLEAR the DTCs. REPEAT the self-test.
------------------------------------------------- I12 CHECK CIRCUIT CLS44 (BU/RD) FOR AN OPEN
- Disconnect: Inoperative Rear Lamp.
- While applying the brake pedal, measure the voltage between the LH rear lamp (LED module)
C419-1, circuit CLS44 (BU/RD), harness side and ground; or between the RH rear lamp (LED
module) C418-1, circuit CLS44 (BU/RD), harness side and ground.
- Is the voltage greater than 10 volts?
Yes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8520
INSTALL a new LED module. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- I13 CHECK THE REAR STOPLAMP VOLTAGE SUPPLY
CIRCUIT FOR AN OPEN
- Disconnect: Inoperative Rear Lamp.
- Disconnect: SJB C2280a.
- Measure the resistance between the inoperative rear lamp, harness side and the SJB, harness
side as follows:
- Is the resistance less than 5 ohms?
Yes
GO to I15.
No
REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test.
------------------------------------------------- I14 CHECK CIRCUIT GD148 (BK/YE) FOR AN OPEN
- Place the headlamp switch in the PARKING LAMPS ON position.
- Are both rear parking lamps inoperative?
Yes
REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
No
GO to I15.
------------------------------------------------- I15 CHECK FOR CORRECT SJB OPERATION
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8521
Yes
INSTALL a new SJB. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the self-test.
------------------------------------------------Pinpoint Test H: All The Stoplamps Are Inoperative
Stoplamps
Pinpoint Tests
Pinpoint Test H: All The Stoplamps Are Inoperative
Refer to Wiring Diagram Set 90, Turn Signal/Stop/Hazard Lamps for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
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
PINPOINT TEST H: ALL THE STOPLAMPS ARE INOPERATIVE
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
------------------------------------------------- H1 CHECK CIRCUIT SBP22 (BN/RD) FOR VOLTAGE
- Ignition OFF.
- Disconnect: Stoplamp Switch C278.
- Measure the voltage between the stoplamp switch C278-1, circuit SBP22 (BN/RD), harness side
and ground.
- Is the voltage greater than 10 volts?
Yes
GO to H3.
No
VERIFY the SJB fuse 22 (15A) is OK. If OK, GO to H2. If not OK, REFER to the Wiring Diagrams
to identify the possible causes of the circuit short.
------------------------------------------------- H2 CHECK CIRCUIT SBP22 (BN/RD) FOR AN OPEN
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8522
- Disconnect: SJB C2280e.
- Measure the resistance between the stoplamp switch C278-1, circuit SBP22 (BN/RD), harness
side and the SJB C2280e-28, circuit SBP22 (BN/RD), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to H5.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- H3 CHECK THE STOPLAMP SWITCH
- Connect a fused jumper wire between the stoplamp switch C278-1, circuit SBP22 (BN/RD),
harness side and the stoplamp switch C278-4, circuit CCB08 (VT/WH), harness side.
- Do the stoplamps illuminate?
Yes
REMOVE the jumper wire. INSTALL a new stoplamp switch. REFER to Stoplamp Switch See:
Brake Light Switch/Service and Repair. TEST the system for normal operation.
No
REMOVE the jumper wire. GO to H4.
------------------------------------------------- H4 CHECK CIRCUIT CCB08 (VT/WH) FOR AN OPEN
- Disconnect: SJB C2280e.
- Measure the resistance between the stoplamp switch C278-4, circuit CCB08 (VT/WH), harness
side and the SJB C2280e-23, circuit CCB08 (VT/WH), harness side.
Is the resistance less than 5 ohms?
Yes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8523
GO to H5.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- H5 CHECK FOR CORRECT SJB OPERATION
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new SJB. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector.
------------------------------------------------Pinpoint Test J: The Stoplamps Are On Continuously
Stoplamps
Pinpoint Tests
Pinpoint Test J: The Stoplamps Are On Continuously
Refer to Wiring Diagram Set 90, Turn Signal/Stop/Hazard Lamps for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 42, Vehicle Dynamic Systems for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
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 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).
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) - 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) - 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) - 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:
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8524
- Wiring, terminals or connectors
- Stoplamp switch
- TBC module
- Brake shift interlock actuator
- ABS module
- PCM
- SJB
PINPOINT TEST J: THE STOPLAMPS ARE ON CONTINUOUSLY
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
------------------------------------------------- J1 DETERMINE IF ALL THE STOPLAMPS ARE
ILLUMINATED
- Ignition OFF.
- Observe the stoplamps with the brake pedal released.
- Are all of the stoplamps illuminated?
Yes
GO to J2.
No
GO to J9.
------------------------------------------------- J2 CHECK THE STOPLAMP SWITCH
- Disconnect: Stoplamp Switch C278.
- Do the stoplamps continue to illuminate?
Yes
GO to J3.
No
INSTALL a new stoplamp switch. REFER to Stoplamp Switch See: Brake Light Switch/Service and
Repair. CLEAR the DTCs. REPEAT the self-test.
------------------------------------------------- J3 CHECK THE BRAKE SHIFT INTERLOCK ACTUATOR
- Disconnect: Brake Shift Interlock Actuator C2008.
- Do the stoplamps continue to illuminate?
Yes
GO to J4.
No
INSTALL a new brake shift interlock actuator. CLEAR the DTCs. REPEAT the self-test.
------------------------------------------------- J4 CHECK THE ABS MODULE
- Disconnect: ABS Module C155.
- Do the stoplamps continue to illuminate?
Yes
If equipped with a Trailer Brake Control (TBC) module, GO to J5.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8525
If not equipped with a TBC module, GO to J6.
No
GO to J10.
------------------------------------------------- J5 CHECK THE TBC MODULE
- Disconnect: TBC Module C238.
- Do the stoplamps continue to illuminate?
Yes
GO to J6.
No
INSTALL a new TBC module. CLEAR the DTCs. REPEAT the self-test.
------------------------------------------------- J6 CHECK THE PCM
- Disconnect: PCM C175b.
- Do the stoplamps continue to illuminate?
Yes
GO to J7.
No
GO to J12.
------------------------------------------------- J7 CHECK CIRCUIT CCB08 (VT/WH) FOR A SHORT TO
VOLTAGE (TO OTHER MODULES)
- Disconnect: SJB C2280c.
- Do the stoplamps continue to illuminate?
Yes
GO to J8.
No
REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
------------------------------------------------- J8 CHECK CIRCUIT CCB08 (VT/WH) FOR A SHORT TO
VOLTAGE (FROM STOPLAMP SWITCH)
- Disconnect: SJB C2280e.
- Do the stoplamps continue to illuminate?
Yes
GO to J9.
No
REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
------------------------------------------------- J9 CHECK CIRCUIT CCB08 (VT/WH) FOR A SHORT TO
VOLTAGE (TO HIGH MOUNTED STOPLAMP)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8526
- Disconnect: SJB C2280a.
- Do the stoplamps continue to illuminate?
Yes
If the high mounted stoplamp continues to illuminate, REPAIR circuit CCB08 (VT/WH). CLEAR the
DTCs. REPEAT the self-test.
For Explorer or Explorer Sport Trac, if the LH rear lamp continues to illuminate, REPAIR circuit
CLS18 (GY/BN). CLEAR the DTCs. REPEAT the self-test. If the RH rear lamp continues to
illuminate, REPAIR circuit CLS19 (VT/OG). CLEAR the DTCs. REPEAT the self-test.
For Mountaineer, if the rear lamps continue to illuminate, REPAIR circuit CLS44 (VT/BN). CLEAR
the DTCs. REPEAT the self-test.
No
GO to J11.
------------------------------------------------- J10 CHECK FOR CORRECT ABS MODULE OPERATION
- Disconnect the ABS module connector.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect the ABS module connector and make sure it seats correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new ABS module. CLEAR the DTCs. REPEAT the self-test.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the self-test.
------------------------------------------------- J11 CHECK FOR CORRECT SJB OPERATION
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new SJB. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the self-test.
------------------------------------------------- J12 CHECK FOR CORRECT PCM OPERATION
- Disconnect all the PCM connectors.
- Check for: corrosion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Inspection and Diagnostic Overview > Page 8527
- damaged pins
- pushed-out pins
- Connect all the PCM connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new PCM. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the self-test.
-------------------------------------------------
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations
Brake Light Switch: Locations
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Brake Light Switch: Description and Operation
Engine Control Components
Brake Pedal Position (BPP) Switch
The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal
to the PCM indicating the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Typical BPP Switch
Typical BPP Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Brake Light Switch: Service and Repair
Stoplamp Switch
Removal and Installation
NOTICE: Do not remove or repair the brake pedal, brake booster or master cylinder without first
removing the stoplamp switch. Do not install the stoplamp switch without the brake pedal arm
secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or
installing the stoplamp switch, as misadjustment or damage to the switch may occur.
1. Disconnect the stoplamp switch electrical connector.
2. Rotate the stoplamp switch 45 degrees clockwise and remove the stoplamp switch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Cargo Lamp
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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8539
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Daytime Running Lamp: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in 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.
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.
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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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information and Instructions > Page 8552
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information and Instructions > Page 8553
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8554
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
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8555
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery 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 loose
clothing.
Symbols
Symbols (Part 1)
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Information and Instructions > Page 8556
Symbols (Part 2)
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Information and Instructions > Page 8557
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information and Instructions > Page 8558
Symbols (Part 4)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8559
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8560
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.
Defective insulation stripping
1 = Proper crimp
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8561
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information and Instructions > Page 8562
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8563
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8564
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information and Instructions > Page 8565
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.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information and Instructions > Page 8566
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 Explorer 2wd Workshop Manual (V6-4.0L (2009))
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Information and Instructions > Page 8568
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8569
Daytime Running Lamp: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
97-1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8570
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 (V6-4.0L (2009))
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
Principles Of Operation
Daytime Running Lamps (DRL)
Principles of Operation
NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM).
The Daytime Running Lamps (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
The DRL is not a programmable parameter for this vehicle.
Special Tools Used With Diagnostics
Daytime Running Lamps (DRL)
Inspection And Verification
Daytime Running Lamps (DRL)
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.
NOTE: 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, No Power To The Scan Tool, to diagnose no power to the scan tool.
5. If the scan tool does not communicate with the vehicle:
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection
> Initial Inspection and Diagnostic Overview > Page 8573
- Verify the ignition key is in the ON position.
- Verify the scan tool operation with a known good vehicle.
- Refer to Information Bus 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.
- 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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection
> Initial Inspection and Diagnostic Overview > Page 8574
Daytime Running Lamp: Symptom Related Diagnostic Procedures
Daytime Running Lamps (DRL)
Symptom Chart
Symptom Chart
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection
> Initial Inspection and Diagnostic Overview > Page 8575
Daytime Running Lamp: Pinpoint Tests
Daytime Running Lamps (DRL)
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 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
PINPOINT TEST AE: THE DRL ARE INOPERATIVE
------------------------------------------------- AE1 VERIFY THE DRL OPERATION
- Ignition ON.
- Place the headlamp switch in the OFF position.
- Place the gear selector lever in any gear other than PARK (P).
- Are the DRL illuminated?
Yes
The system is operating correctly. INFORM the customer of the conditions required for the DRL to
operate correctly.
No
GO to AE2.
------------------------------------------------- AE2 CHECK THE OPERATION OF THE HEADLAMPS
- Place the headlamp switch in the HEADLAMPS ON position and observe the headlamps.
- Do the headlamps operate correctly?
Yes
GO to AE3.
No
REFER to Headlamps See: Headlamp/Testing and Inspection.
------------------------------------------------- AE3 CHECK THE IGNITION SWITCH INPUT
- Place the headlamp switch in the OFF position.
- Enter the following diagnostic mode on the scan tool: SJB DataLogger.
- Monitor the SJB ignition switch PIDs (IGN_A_ECU, IGN_O_ECU, IGN_R_ECU, IGN_S_ECU)
while cycling the ignition switch through all its positions.
- Do the PIDs agree with the ignition switch positions?
Yes
GO to AE4.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection
> Initial Inspection and Diagnostic Overview > Page 8576
No
REFER to Steering Column to diagnose the input from the ignition switch. See: Steering and
Suspension/Steering/Steering Column/Testing and Inspection
------------------------------------------------- AE4 CHECK THE TRANSMISSION GEAR INPUT
- Enter the following diagnostic mode on the scan tool: PCM or TCM DataLogger.
- Monitor the PCM or TCM transmission gear status PID (TR) while placing the gear selector lever
through all its positions.
- Does the PID agree with the gear selection?
Yes
INSTALL a new SJB. TEST the system for normal operation.
No
REFER to Transmission Control Systems to diagnose the transmission range input. See:
Powertrain Management/Transmission Control Systems/Testing and Inspection
-------------------------------------------------
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection
> Page 8577
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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair
Dimmer Switch: Service and Repair
Instrument Panel Dimmer Switch
Removal and Installation
1. Remove the driver side register.
2. Remove the headlamp switch and bezel as an assembly.
- Disconnect the electrical connectors.
3. Release the 2 tabs and remove the instrument panel dimmer switch.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior
Lamp - Front
Dome Lamp: Service and Repair Interior Lamp - Front
Interior Lamp - Front
Removal and Installation
1. NOTE: Use a small screwdriver to pry open the garage door opener bin.
Open the rear overhead console storage or garage door opener bin to access the retaining screw.
- Remove the screw.
2. Pull the front of the overhead console down and remove the console from the console retaining
clips.
- Disconnect the electrical connector(s).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior
Lamp - Front > Page 8585
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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior
Lamp - Front > Page 8586
ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch,
Driver Side Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch,
Driver Side Front > Page 8591
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch,
Driver Side Front > Page 8592
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch,
Driver Side Front > Page 8593
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch,
Driver Side Front > Page 8594
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar
Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar
Switch > Page 8597
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar
Switch > Page 8598
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar
Switch > Page 8599
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar
Switch > Page 8600
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal and Installation
1. Remove the front door latch. For additional information, refer to Front Door Latch See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Front Door Latch/Service and Repair/Removal and Replacement/Front Door Latch.
2. Disconnect the front door ajar switch electrical connector.
3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the
switch from the front door latch.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar
Switch - Front Door > Page 8603
Door Switch: Service and Repair Door Ajar Switch - Liftgate
Door Ajar Switch - Liftgate
Removal and Installation
1. Remove the liftgate latch. For additional information, refer to Liftgate Latch See: Body and
Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk
/ Liftgate Latch/Service and Repair/Liftgate Latch.
2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar
switch form the liftgate latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar
Switch - Front Door > Page 8604
Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass
Door Ajar Switch - Liftgate Glass
Removal and Installation
1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See:
Body and Frame/Doors, Hood and
Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/Liftgate Window Latch.
2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the
liftgate window latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar
Switch - Front Door > Page 8605
Door Switch: Service and Repair Door Ajar Switch - Rear Door
Door Ajar Switch - Rear Door
Removal and Installation
1. Remove the rear door latch. For additional information, refer to Rear Door Latch See: Body and
Frame/Doors, Hood and Trunk/Doors/Rear
Door/Rear Door Latch/Service and Repair/Removal and Replacement/Rear Door Latch.
2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch
from the rear door latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
NOTE: Explorer, Explorer Sport Trac shown, Mountaineer similar.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information >
Service and Repair > Page 8610
NOTE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations > Page 8614
Fog/Driving Lamp Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations > Page 8615
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions
Hazard Warning Lamps: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8620
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8621
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8622
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8623
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
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8624
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery 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 loose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8625
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8626
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8627
Symbols (Part 4)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8628
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8629
Hazard Warning 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.
Defective insulation stripping
1 = Proper crimp
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8630
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8631
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8632
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8633
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8634
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.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8635
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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8636
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8637
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8638
Hazard Warning 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.
90-3
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Information and Instructions > Page 8639
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 (V6-4.0L (2009))
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
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. For additional information, refer to Headlamp Assembly See:
Service and Repair.
2. Rotate the headlamp bulb one-eighth turn counterclockwise and remove the headlamp bulb.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Illumination Dimmer Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Illumination Dimmer Switch > Page 8648
Headlamp Dimmer Switch: Locations Multifunction Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Illumination Dimmer Switch > Page 8649
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Multifunction Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Multifunction Switch > Page 8652
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing
and Inspection > Illumination Dimmer Switch
Headlamp Dimmer Switch: Testing and Inspection Illumination Dimmer Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing
and Inspection > Illumination Dimmer Switch > Page 8655
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing
and Inspection > Illumination Dimmer Switch > Page 8656
Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing
and Inspection > Illumination Dimmer Switch > Page 8657
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing
and Inspection > Page 8658
Headlamp Dimmer Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Removal and Installation
NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Remove the 2 screws and the steering column opening cover.
2. Remove the 3 screws and the upper and lower steering column shrouds.
3. Disconnect the multifunction switch electrical connector.
4. Remove the 2 multifunction switch screws and the multifunction switch.
- To install, tighten to 3 Nm (27 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations >
Page 8662
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations >
Page 8663
Headlamp Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations >
Page 8664
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations >
Page 8665
Headlamp Switch: Service and Repair
Headlamp Switch
Removal and Installation
1. Remove the driver side register.
2. Remove the headlamp switch and bezel as an assembly.
- Disconnect the electrical connectors.
3. Remove the 3 screws and the headlamp switch.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions
License Plate Lamp: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8674
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8675
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8676
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8677
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
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8678
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery 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 loose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8679
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8680
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8681
Symbols (Part 4)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8682
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8683
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.
Defective insulation stripping
1 = Proper crimp
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8684
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8685
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8686
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8687
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8688
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.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8689
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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8690
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8691
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8692
License Plate Lamp: Connector Views
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8693
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8694
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8695
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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8696
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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Marker Lamp: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8701
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8702
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8703
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8704
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
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8705
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery 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 loose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8706
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8707
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8708
Symbols (Part 4)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8709
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8710
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.
Defective insulation stripping
1 = Proper crimp
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8711
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8712
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8713
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8714
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8715
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.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8716
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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8717
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8718
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8719
Marker Lamp: Connector Views
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8720
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8721
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8722
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8723
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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8724
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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 8725
Marker Lamp: Service and Repair
Side Marker Lamp
NOTE: LH front shown, others similar.
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the socket from the side marker lamp.
3. Remove the 2 nuts and the side marker lamp.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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. For additional information, refer to Headlamp Assembly See:
Headlamp/Service and Repair.
2. Remove the parking lamp bulb socket from the headlamp assembly.
- Remove the parking lamp bulb from the socket.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 8737
Fog/Driving Lamp Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 8738
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > Page 8745
Trailer Lighting Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > Page 8746
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 8751
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 8752
Ambient Light Sensor: Service and Repair
Light Sensor
Removal and Installation
1. Position the top portion of the lower center instrument panel finish panel rearward.
2. Remove the upper center instrument panel finish panel.
- Disconnect the electrical connector.
3. Remove the 2 screws and the light sensor.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations
Backup Lamp Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Page 8756
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Page 8757
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
Brake Light Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 8761
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 8762
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 8763
Brake Light Switch: Description and Operation
Engine Control Components
Brake Pedal Position (BPP) Switch
The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal
to the PCM indicating the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Typical BPP Switch
Typical BPP Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 8764
Brake Light Switch: Service and Repair
Stoplamp Switch
Removal and Installation
NOTICE: Do not remove or repair the brake pedal, brake booster or master cylinder without first
removing the stoplamp switch. Do not install the stoplamp switch without the brake pedal arm
secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or
installing the stoplamp switch, as misadjustment or damage to the switch may occur.
1. Disconnect the stoplamp switch electrical connector.
2. Rotate the stoplamp switch 45 degrees clockwise and remove the stoplamp switch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front > Page 8769
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front > Page 8770
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front > Page 8771
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front > Page 8772
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch > Page 8775
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch > Page 8776
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch > Page 8777
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch > Page 8778
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal and Installation
1. Remove the front door latch. For additional information, refer to Front Door Latch See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Front Door Latch/Service and Repair/Removal and Replacement/Front Door Latch.
2. Disconnect the front door ajar switch electrical connector.
3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the
switch from the front door latch.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8781
Door Switch: Service and Repair Door Ajar Switch - Liftgate
Door Ajar Switch - Liftgate
Removal and Installation
1. Remove the liftgate latch. For additional information, refer to Liftgate Latch See: Body and
Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk
/ Liftgate Latch/Service and Repair/Liftgate Latch.
2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar
switch form the liftgate latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8782
Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass
Door Ajar Switch - Liftgate Glass
Removal and Installation
1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See:
Body and Frame/Doors, Hood and
Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/Liftgate Window Latch.
2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the
liftgate window latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 8783
Door Switch: Service and Repair Door Ajar Switch - Rear Door
Door Ajar Switch - Rear Door
Removal and Installation
1. Remove the rear door latch. For additional information, refer to Rear Door Latch See: Body and
Frame/Doors, Hood and Trunk/Doors/Rear
Door/Rear Door Latch/Service and Repair/Removal and Replacement/Rear Door Latch.
2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch
from the rear door latch.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Illumination Dimmer Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Illumination Dimmer Switch > Page 8788
Headlamp Dimmer Switch: Locations Multifunction Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Illumination Dimmer Switch > Page 8789
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Multifunction Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Multifunction Switch > Page 8792
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Testing and Inspection > Illumination Dimmer Switch
Headlamp Dimmer Switch: Testing and Inspection Illumination Dimmer Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 8795
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 8796
Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 8797
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Testing and Inspection > Page 8798
Headlamp Dimmer Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Removal and Installation
NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Remove the 2 screws and the steering column opening cover.
2. Remove the 3 screws and the upper and lower steering column shrouds.
3. Disconnect the multifunction switch electrical connector.
4. Remove the 2 multifunction switch screws and the multifunction switch.
- To install, tighten to 3 Nm (27 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 8802
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 8803
Headlamp Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 8804
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 8805
Headlamp Switch: Service and Repair
Headlamp Switch
Removal and Installation
1. Remove the driver side register.
2. Remove the headlamp switch and bezel as an assembly.
- Disconnect the electrical connectors.
3. Remove the 3 screws and the headlamp switch.
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
Turn Signal Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 8812
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 8813
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 8814
Turn Signal Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 8815
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 8816
Turn Signal Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Removal and Installation
NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Remove the 2 screws and the steering column opening cover.
2. Remove the 3 screws and the upper and lower steering column shrouds.
3. Disconnect the multifunction switch electrical connector.
4. Remove the 2 multifunction switch screws and the multifunction switch.
- To install, tighten to 3 Nm (27 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Tail Lamp: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8821
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8822
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8823
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8824
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
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8825
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery 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 loose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8826
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8827
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8828
Symbols (Part 4)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8829
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8830
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.
Defective insulation stripping
1 = Proper crimp
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8831
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8832
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8833
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8834
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8835
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.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8836
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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8837
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8838
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8839
Tail Lamp: Connector Views
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8840
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8841
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8842
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8843
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8844
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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8845
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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions
Trailer Lamps: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8850
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8851
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8852
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8853
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
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8854
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery 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 loose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8855
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8856
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8857
Symbols (Part 4)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8858
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8859
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.
Defective insulation stripping
1 = Proper crimp
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8860
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8861
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8862
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8863
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8864
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.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8865
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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8866
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8867
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8868
Trailer Lamps: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
95-1
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8869
95-2
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 8870
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 (V6-4.0L (2009))
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
Special Tools Used With Diagnostics
Trailer Lamps
Principles Of Operation
Trailer Lamps
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 stop/turn lamps.
The trailer parking and reversing lamps share the vehicle lighting outputs.
The vehicle is supplied with wiring to support an aftermarket .
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 Field-Effect Transistor (FET) protective circuit strategy for many of its outputs
(for example, a 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 event is detected. A continuous DTC is stored at the fault event and a
cumulative counter is started.
When the demand for the output is no longer present, the module resets the FET circuit protection
to allow the circuit to function. The next time the driver requests a circuit to activate that has been
shut down by a previous short (FET protection) and the circuit remains shorted, the FET protection
shuts off the circuit again and the cumulative counter advances.
When the excessive circuit load occurs often enough, the module shuts down the output until a
repair procedure is carried out. Each FET protected circuit has 3 predefined levels of short circuit
tolerance based on the harmful effect of each circuit fault on the FET and the ability of the FET to
withstand it. A module lifetime level of fault events is established based upon the durability of the
FET. If the total tolerance level is determined to be 600 fault events, the 3 predefined levels would
be 200, 400 and 600 fault events.
When each tolerance level is reached, 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 operation until a successful self-test proves that
the fault has been repaired. After the self-test has successfully completed (no on-demand DTCs
present), the continuous DTC automatically clears and the circuit function returns.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8873
When the first or second level is reached, the continuous DTC (associated with the short circuit)
sets along with DTC B106E. These DTCs can be cleared using the module on-demand self-test,
then the Clear DTC operation on the scan tool (if the on-demand test shows the fault corrected).
The module never resets the fault event counter to zero and continues to advance the fault event
counter as short circuit fault events occur.
If the number of short circuit fault events reach the third level, then DTCs B106F and B1342 set
along with the associated continuous DTC. This DTC 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
Trailer Lamps
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
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.
NOTE: Make sure the multifunction switch is in the LOW BEAM position.
5. 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).
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, No Power To The Scan Tool, to diagnose no power to 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 to diagnose no response from the PCM.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8874
8. Carry out the network test.
- If the scan tool responds with no communication with the SJB, refer to Information Bus.
- 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 Diagnostic Trouble Code (DTC) Chart
See: Testing and Inspection. For all other DTCs,
refer to the Diagnostic Trouble Code (DTC) Chart in Body Control Systems. See: Body and
Frame/Body Control Systems/Testing and Inspection/Diagnostic Trouble Code
Descriptions/Diagnostic Trouble Code (DTC) Chart
11. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8875
Trailer Lamps: Symptom Related Diagnostic Procedures
Trailer Lamps
Symptom Chart
Symptom Chart (Part 1)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8876
Symptom Chart (Part 2)
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8877
Trailer Lamps: Pinpoint Tests
Pinpoint Test W: All The Trailer Lamps Are Inoperative
Trailer Lamps
Pinpoint Tests
Pinpoint Test W: All the Trailer Lamps Are Inoperative
Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
Normal Operation
Ground for all the 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
PINPOINT TEST W: ALL THE TRAILER LAMPS ARE INOPERATIVE
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of
corrosion or damage. Repair or install a new trailer tow connector as required.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- W1 CHECK CIRCUIT RAT08 (WH) FOR AN OPEN TO THE
TRAILER TOW CONNECTOR
- Disconnect the trailer from the vehicle.
- Disconnect: Negative Battery Cable.
- For the 4-pin connector, measure the resistance between the trailer tow C439-4, circuit RAT08
(WH), harness side and ground.
- For the 7-pin connector, measure the resistance between the trailer tow connector pin 2, circuit
RAT08 (WH), component side and ground.
- Is the resistance less than 5 ohms?
Yes
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
No
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8878
For the 4-pin connector, REPAIR the circuit. TEST the system for normal operation.
For the 7-pin connector, GO to W2.
------------------------------------------------- W2 CHECK CIRCUIT RAT08 (WH) FOR AN OPEN
- Disconnect: Trailer Tow C473.
- Measure the resistance between the trailer tow C473-2, circuit RAT08 (WH), harness side and
ground.
- Is the resistance less than 5 ohms?
Yes
INSTALL a new trailer tow connector. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------Pinpoint Test X: The Trailer Lamps Are Inoperative - Parking Lamps
Trailer Lamps
Pinpoint Tests
Pinpoint Test X: The Trailer Lamps Are Inoperative - Parking Lamps
Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
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
PINPOINT TEST X: THE TRAILER LAMPS ARE INOPERATIVE - PARKING LAMPS
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of
corrosion or damage. Repair or install a new trailer tow connector as required.
------------------------------------------------- X1 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR
- Ignition OFF.
- Disconnect the trailer from the vehicle.
- Place the headlamp switch in the PARKING LAMPS ON position.
- For the 4-pin connector, measure the voltage between the trailer tow C439-3, circuit CAT17 (BN),
harness side and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8879
- For the 7-pin connector, measure the voltage between the trailer tow connector pin 6, circuit
CAT17 (BN), component side and ground.
- Is the voltage greater than 10 volts?
Yes
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
No
VERIFY the SJB fuse 25 (15A) is OK.
If OK for the 4-pin connector, GO to X3.
If OK for the 7-pin connector, GO to X2.
If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short.
------------------------------------------------- X2 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR (7-PIN)
- Disconnect: Trailer Tow C473.
- Measure the voltage between the trailer tow C473-6, circuit CAT17 (BN), harness side and
ground.
- Is the voltage greater than 10 volts?
Yes
INSTALL a new trailer tow connector. TEST the system for normal operation.
No
GO to X3.
------------------------------------------------- X3 CHECK CIRCUIT CAT17 (BN) FOR AN OPEN
- Place the headlamp switch in the OFF position.
- Disconnect: SJB C2280a.
- Measure the resistance between the SJB C2280a-13, circuit CAT17 (BN), harness side and the
trailer tow C439-3 (4-pin connector) or C473-6 (7-pin connector), circuit CAT17 (BN), harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8880
- Is the resistance less than 5 ohms?
Yes
GO to X4.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- X4 CHECK FOR CORRECT SJB OPERATION
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new SJB. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector.
------------------------------------------------Pinpoint Test Y: The Trailer Lamps Are Inoperative - Reversing Lamps
Trailer Lamps
Pinpoint Tests
Pinpoint Test Y: The Trailer Lamps Are Inoperative - Reversing Lamps
Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
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
PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE - REVERSING LAMPS
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8881
connector.
NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of
corrosion or damage. Repair or install a new trailer tow connector as required.
------------------------------------------------- Y1 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR
- Ignition OFF.
- Disconnect the trailer from the vehicle.
- Apply the parking brake.
- Ignition ON.
- Select REVERSE.
- Measure the voltage between the trailer tow connector pin 7, circuit CAT16 (GY/BN), component
side and ground.
- Is the voltage greater than 10 volts?
Yes
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
No
VERIFY the SJB fuse 16 (10A) is OK. If OK, GO to Y2. If not OK, REFER to the Wiring Diagrams
to identify the possible causes of the circuit short.
------------------------------------------------- Y2 CHECK FOR VOLTAGE ON CIRCUIT CAT16 (GY/BN)
- Disconnect: Trailer Tow C473.
- Measure the voltage between the trailer tow C473-7, circuit CAT16 (GY/BN), harness side and
ground.
- Is the voltage greater than 10 volts?
Yes
INSTALL a new trailer tow connector. TEST the system for normal operation.
No
GO to Y3.
------------------------------------------------- Y3 CHECK CIRCUIT CAT16 (GY/BN) FOR AN OPEN
- Select PARK.
- Ignition OFF.
- Disconnect: SJB C2280a.
- Measure the resistance between the SJB C2280a-21, circuit CAT16 (GY/BN), harness side and
the trailer tow C473-7, circuit CAT16 (GY/BN), harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8882
- Is the resistance less than 5 ohms?
Yes
GO to Y4.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- Y4 CHECK FOR CORRECT SJB OPERATION
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new SJB. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector.
------------------------------------------------Pinpoint Test Z: The Individual Trailer Lamp Is Inoperative - LH Stop/Turn Lamp
Trailer Lamps
Pinpoint Tests
Pinpoint Test Z: The Individual Trailer Lamp Is Inoperative - LH Stop/Turn Lamp
Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
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) - 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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8883
PINPOINT TEST Z: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - LH STOP/TURN LAMP
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of
corrosion or damage. Repair or install a new trailer tow connector as required.
------------------------------------------------- Z1 CHECK THE RECORDED DTCs FROM THE SJB
SELF-TEST
- Check the recorded results from the SJB self-test.
- Was DTC B2070 present?
Yes
GO to Z2.
No
GO to Z6.
------------------------------------------------- Z2 CLEAR THE DTCs AND REPEAT THE ON-DEMAND
SELF-TEST WITH THE TRAILER DISCONNECTED
- Disconnect the trailer from the vehicle.
- Enter the following diagnostic mode on the scan tool: SJB Self-Test.
- Clear the continuous DTCs. Repeat the on-demand self-test.
- Is DTC B2070 still present?
Yes
For the 4-pin connector, GO to Z5.
For the 7-pin connector, GO to Z4.
No
GO to Z3.
------------------------------------------------- Z3 CHECK THE NUMBER OF BULBS ON THE TRAILER
- Inspect the trailer for more than 2 LH stop/turn lamp bulbs.
- Are more than 2 LH stop/turn lamp bulbs present?
Yes
INFORM the customer that the vehicle can only support 2 stop/turn lamp bulbs per side. Any
additional stop/turn lamp bulbs need to be removed from the trailer or an adapter kit installed for
the trailer tow lamps to operate correctly.
No
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
------------------------------------------------- Z4 CHECK THE TRAILER TOW CONNECTOR
- Disconnect: Trailer Tow C473.
- Enter the following diagnostic mode on the scan tool: SJB Self-Test.
- Clear the continuous DTCs. Repeat the on-demand self-test.
- Is DTC B2070 still present?
Yes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8884
GO to Z5.
No
INSTALL a new trailer tow connector. TEST the system for normal operation.
------------------------------------------------- Z5 CHECK CIRCUIT CAT06 (YE) FOR A SHORT TO
GROUND
- Ignition OFF.
- Disconnect: SJB C2280a.
- Measure the resistance between the SJB C2280a-14, circuit CAT06 (YE), harness side and
ground.
- Is the resistance greater than 10,000 ohms?
Yes
GO to Z9.
No
REPAIR the circuit. RUN the on-demand self-test (required to clear certain DTCs). CORRECT any
unresolved DTCs. CLEAR all DTCs. TEST the system for normal operation.
------------------------------------------------- Z6 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR
- Disconnect the trailer from the vehicle.
- Ignition OFF.
- For the 4-pin connector, while applying the brake pedal, measure the voltage between the trailer
tow C439-2, circuit CAT06 (YE), harness side and ground.
- For the 7-pin connector, while applying the brake pedal, measure the voltage between the trailer
tow connector pin 1, circuit CAT06 (YE), component side and ground.
- Is the voltage greater than 10 volts?
Yes
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
TEST the system for normal operation.
No
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8885
For the 4-pin connector, GO to Z8.
For the 7-pin connector, GO to Z7.
------------------------------------------------- Z7 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR (7-PIN)
- Disconnect: Trailer Tow C473.
- While applying the brake pedal, measure the voltage between the trailer tow C473-1, circuit
CAT06 (YE), harness side and ground.
- Is the voltage greater than 10 volts?
Yes
INSTALL a new trailer tow connector. TEST the system for normal operation.
No
GO to Z8.
------------------------------------------------- Z8 CHECK CIRCUIT CAT06 (YE) FOR AN OPEN
- Disconnect: SJB C2280a.
- Measure the resistance between the SJB C2280a-14, circuit CAT06 (YE), harness side and the
trailer tow C439-2 (4-pin) or C473-1 (7-pin), circuit CAT06 (YE), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to Z9.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- Z9 CHECK FOR CORRECT SJB OPERATION
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8886
INSTALL a new SJB. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the self-test.
------------------------------------------------Pinpoint Test AA: The Individual Trailer Lamp Is Inoperative - RH Stop/Turn Lamp
Trailer Lamps
Pinpoint Tests
Pinpoint Test AA: The Individual Trailer Lamp Is Inoperative - RH Stop/Turn Lamp
Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
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) - 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
PINPOINT TEST AA: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - RH STOP/TURN
LAMP
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of
corrosion or damage. Repair or install a new trailer tow connector as required.
------------------------------------------------- AA1 CHECK THE RECORDED DTCs FROM THE SJB
SELF-TEST
- Check the recorded results from the SJB self-test.
- Was DTC B2070 present?
Yes
GO to AA2.
No
GO to AA6.
------------------------------------------------- AA2 CLEAR THE DTCs AND REPEAT THE ON-DEMAND
SELF-TEST WITH THE TRAILER DISCONNECTED
- Disconnect the trailer from the vehicle.
- Enter the following diagnostic mode on the scan tool: SJB Self-Test.
- Clear the continuous DTCs. Repeat the on-demand self-test.
- Is DTC B2070 still present?
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8887
Yes
For the 4-pin connector, GO to AA5.
For the 7-pin connector, GO to AA4.
No
GO to AA3.
------------------------------------------------- AA3 CHECK THE NUMBER OF BULBS ON THE TRAILER
- Inspect the trailer for more than 2 RH stop/turn lamp bulbs.
- Are more than 2 RH stop/turn lamp bulbs present?
Yes
INFORM the customer that the vehicle can only support 2 stop/turn lamp bulbs per side. Any
additional stop/turn lamp bulbs need to be removed from the trailer or an adapter kit installed for
the trailer tow lamps to operate correctly.
No
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
------------------------------------------------- AA4 CHECK THE TRAILER TOW CONNECTOR
- Disconnect: Trailer Tow 473.
- Enter the following diagnostic mode on the scan tool: SJB Self-Test.
- Clear the continuous DTCs. Repeat the on-demand self-test.
- Is DTC B2070 still present?
Yes
GO to AA5.
No
INSTALL a new trailer tow connector. TEST the system for normal operation.
------------------------------------------------- AA5 CHECK CIRCUIT CAT09 (GN) FOR A SHORT TO
GROUND
- Ignition OFF.
- Disconnect: SJB C2280a.
- Measure the resistance between the SJB C2280a-26, circuit CAT09 (GN), harness side and
ground.
- Is the resistance greater than 10,000 ohms?
Yes
GO to AA9.
No
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8888
REPAIR the circuit. RUN the on-demand self-test (required to clear certain DTCs). CORRECT any
unresolved DTCs. CLEAR all DTCs. TEST the system for normal operation.
------------------------------------------------- AA6 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR
- Ignition OFF.
- Disconnect the trailer from the vehicle.
- For the 4-pin connector, while applying the brake pedal, measure the voltage between the trailer
tow C439-1, circuit CAT09 (GN), harness side and ground.
- For the 7-pin connector, while applying the brake pedal, measure the voltage between the trailer
tow connector pin 4, circuit CAT09 (GN), component side and ground.
- Is the voltage greater than 10 volts?
Yes
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
TEST the system for normal operation.
No
For the 4-pin connector, GO to AA8.
For the 7-pin connector, GO to AA7.
------------------------------------------------- AA7 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR (7-PIN)
- Disconnect: Trailer Tow C473.
- While applying the brake pedal, measure the voltage between the trailer tow C473-4, circuit
CAT09 (GN), harness side and ground.
- Is the voltage greater than 10 volts?
Yes
INSTALL a new trailer tow connector. TEST the system for normal operation.
No
GO to AA8.
------------------------------------------------- AA8 CHECK CIRCUIT CAT09 (GN) FOR AN OPEN
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8889
- Disconnect: SJB C2280a.
- Measure the resistance between the SJB C2280a-26, circuit CAT09 (GN), harness side and the
trailer tow C439-1 (4-pin) or C473-4 (7-pin), circuit CAT09 (GN), harness side.
- Is the resistance less than 5 ohms?
Yes
GO to AA9.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- AA9 CHECK FOR CORRECT SJB OPERATION
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new SJB. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT the self-test.
------------------------------------------------Pinpoint Test AB: The Trailer Lamps Are On Continuously
Trailer Lamps
Pinpoint Tests
Pinpoint Test AB: The Trailer Lamps Are On Continuously
Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
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.
The trailer tow parking lamps share the same voltage supply with the vehicle parking lamps.
This pinpoint test is intended to diagnose the following:
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8890
- Wiring, terminals or connectors
- Trailer
- SJB
PINPOINT TEST AB: THE TRAILER LAMPS ARE ON CONTINUOUSLY
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of
corrosion or damage. Repair or install a new trailer tow connector as required.
------------------------------------------------- AB1 CHECK FOR VOLTAGE AT THE TRAILER TOW
CONNECTOR
- Ignition OFF.
- Disconnect the trailer from the vehicle.
- Ignition ON.
- Measure the voltage between the trailer tow connector, harness side and ground as follows:
- Is any voltage present?
Yes
GO to AB2.
No
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
------------------------------------------------- AB2 CHECK THE SJB
- Ignition OFF.
- Disconnect: SJB C2280a.
- Ignition ON.
- Measure the voltage between the trailer tow connector, harness side and ground as follows:
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8891
- Is any voltage present?
Yes
REPAIR the circuit in question. TEST the system for normal operation.
No
GO to AB3.
------------------------------------------------- AB3 CHECK FOR CORRECT SJB OPERATION
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new SJB. CLEAR any DTCs. REPEAT the self-test.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector.
------------------------------------------------Pinpoint Test AC: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly
Trailer Lamps
Pinpoint Tests
Pinpoint Test AC: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly
Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
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 (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8892
PINPOINT TEST AC: THE TRAILER BATTERY CHARGING IS INOPERATIVE/DOES NOT
OPERATE CORRECTLY
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of
corrosion or damage. Repair or install a new trailer tow connector as required.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- AC1 CHECK FOR VOLTAGE AT THE TRAILER TOW
CONNECTION (BATTERY CHARGE INOPERATIVE)
- Ignition OFF.
- Disconnect the trailer from the vehicle.
- Ignition ON.
- Measure the voltage between the trailer tow connector pin 5, circuit CAT14 (OG), component side
and ground.
Is the voltage greater than 10 volts?
Yes
GO to AC8.
No
VERIFY the BJB fuse 13 (30A) is OK. If OK, GO to AC2. If not OK, REFER to the Wiring Diagrams
to identify the possible causes of the circuit short.
------------------------------------------------- AC2 CHECK THE TRAILER BATTERY CHARGE RELAY
(INOPERATIVE)
- Ignition OFF.
- Disconnect: Trailer Battery Charge Relay.
- Substitute the trailer battery charge relay with a known good relay.
- Ignition ON.
- Measure the voltage between the trailer tow connector pin 5, circuit CAT14 (OG), component side
and ground.
- Is the voltage greater than 10 volts?
Yes
REMOVE the known good relay. INSTALL a new trailer battery charge relay. TEST the system for
normal operation.
No
REMOVE the known good relay. INSTALL the original relay. GO to AC3.
-------------------------------------------------
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8893
AC3 CHECK THE TRAILER TOW CONNECTOR
- Ignition OFF.
- Disconnect: Trailer Tow C473.
- Ignition ON.
- Measure the voltage between the trailer tow C473-5, circuit CAT14 (OG) and ground.
Is the voltage greater than 10 volts?
Yes
INSTALL a new trailer tow connector. TEST the system for normal operation.
No
GO to AC4.
------------------------------------------------- AC4 CHECK FOR VOLTAGE TO THE TRAILER BATTERY
CHARGE RELAY COIL
- Ignition OFF.
- Disconnect: Trailer Battery Charge Relay.
- Ignition ON.
- Measure the voltage between the trailer battery charge relay pin 86, circuit CBP12 (GN/WH), BJB
face side and ground.
- Is the voltage greater than 10 volts?
Yes
GO to AC6.
No
VERIFY the SJB fuse 12 (5A) is OK. If OK, GO to AC5. If not OK, REFER to the Wiring Diagrams
to identify the possible causes of the circuit short.
------------------------------------------------- AC5 CHECK CIRCUIT CBP12 (GN/WH) FOR AN OPEN
- Ignition OFF.
- Disconnect: SJB C2280e.
- Measure the resistance between trailer battery charge relay pin 86, circuit CBP12 (GN/WH), BJB
face side and the SJB C2280e-6, circuit CBP12 (GN/WH), harness side.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8894
- Is the resistance less than 5 ohms?
Yes
GO to AC12.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- AC6 CHECK CIRCUIT GD120 (BK/GN) FOR AN OPEN
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the trailer battery charge relay pin 85, circuit GD120 (BK/GN),
BJB face side and ground.
- Is the resistance less than 5 ohms?
Yes
GO to AC7.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- AC7 CHECK FOR VOLTAGE TO THE TRAILER BATTERY
CHARGE RELAY
- Measure the voltage between the trailer battery charge relay pin 30, circuit SSB13 (GY/RD), BJB
face side and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8895
- Is the voltage greater than 10 volts?
Yes
REPAIR circuit CAT14 (OG) for an open. TEST the system for normal operation.
No
REPAIR circuit SSB13 (GY/RD) for an open. TEST the system for normal operation.
------------------------------------------------- AC8 CHECK FOR VOLTAGE AT THE TRAILER TOW
CONNECTOR (BATTERY CHARGE ALWAYS ON)
- Ignition OFF.
- Measure the voltage between the trailer tow connector pin 5, circuit CAT14 (OG), component side
and ground.
- Is any voltage present?
Yes
GO to AC9.
No
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
------------------------------------------------- AC9 CHECK CIRCUIT CAT14 (OG) FOR A SHORT TO
VOLTAGE
- Disconnect: Trailer Battery Charge Relay.
- Measure the voltage between the trailer tow connector pin 5, circuit CAT14 (OG), component side
and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8896
- Is any voltage present?
Yes
REPAIR the circuit. TEST the system for normal operation.
No
GO to AC10.
------------------------------------------------- AC10 CHECK THE TRAILER BATTERY CHARGE RELAY
(ALWAYS ON)
- Measure the voltage between the trailer battery charge relay pin 86, circuit CBP12 (GN/WH), BJB
face side and ground.
- Is any voltage present?
Yes
GO to AC11.
No
INSTALL a new trailer battery charge relay. TEST the system for normal operation.
------------------------------------------------- AC11 CHECK CIRCUIT CBP12 (GN/WH) FOR A SHORT TO
VOLTAGE
- Disconnect: SJB C2280e.
- Measure the voltage between the trailer battery charge relay pin 86, circuit CBP12 (GN/WH),
harness side and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8897
Is any voltage present?
Yes
REPAIR the circuit. TEST the system for normal operation.
No
GO to AC12.
------------------------------------------------- AC12 CHECK FOR CORRECT SJB OPERATION
- Disconnect all the SJB connectors.
- Check for: corrosion
- damaged pins
- pushed-out pins
- Connect all the SJB connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new SJB. CLEAR any DTCs. REPEAT the self-test.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector.
------------------------------------------------Pinpoint Test AD: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly
Trailer Lamps
Pinpoint Tests
Pinpoint Test AD: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly
Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information.
See: Diagrams/Electrical Diagrams/Diagrams By Number
Normal Operation
The 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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8898
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- TBC module
- Trailer tow connector
- Trailer
PINPOINT TEST AD: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE/DO NOT
OPERATE CORRECTLY
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of
corrosion or damage. Repair or install a new trailer tow connector as required.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- AD1 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR (INOPERATIVE CONDITION)
- Ignition OFF.
- Disconnect the trailer from the vehicle.
- While applying the brake pedal, measure the voltage between the trailer tow connector pin 3,
circuit CAT19 (BU), component side and ground.
- Is the voltage greater than 10 volts?
Yes
GO to AD8.
No
GO to AD2.
------------------------------------------------- AD2 CHECK THE TRAILER TOW CONNECTOR
- Disconnect: Trailer Tow C473.
- While applying the brake pedal, measure the voltage between the trailer tow C473-3, circuit
CAT19 (BU), harness side and ground.
- Is the voltage greater than 10 volts?
Yes
INSTALL a new trailer tow connector. TEST the system for normal operation.
No
GO to AD3.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8899
------------------------------------------------- AD3 CHECK CIRCUIT SBB17 (RD) FOR AN OPEN
- Disconnect: C238.
- Measure the voltage between the TBC module C238-1, circuit SBB17 (RD), harness side and
ground.
- Is the voltage greater than 10 volts?
Yes
GO to AD4.
No
VERIFY the BJB fuse 17 (30A) is OK. If OK, REPAIR the circuit. TEST the system for normal
operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit
short.
------------------------------------------------- AD4 CHECK CIRCUIT CCB08 (VT/WH) FOR AN OPEN
- While applying the brake pedal, measure the voltage between the TBC module C238-2, circuit
CCB08 (VT/WH), harness side and ground.
- Is the voltage greater than 10 volts?
Yes
GO to AD5.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- AD5 CHECK CIRCUIT GD138 (BK/WH) FOR AN OPEN
- Disconnect: Negative Battery Cable.
- Measure the resistance between the TBC module C238-6, circuit GD138 (BK/WH), harness side
and ground.
- Is the resistance less than 5 ohms?
Yes
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8900
GO to AD6.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- AD6 CHECK CIRCUIT CAT19 (BU) FOR A SHORT TO
GROUND
- Measure the resistance between the TBC module C238-3, circuit CAT19 (BU), harness side and
ground.
- Is the resistance greater than 10,000 ohms?
Yes
GO to AD7.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- AD7 CHECK CIRCUIT CAT19 (BU) FOR AN OPEN
- Measure the resistance between the TBC module C238-3, circuit CAT19 (BU), harness side and
the trailer tow C473-3, circuit CAT19 (BU), harness side.
- Is the resistance less than 5 ohms?
Yes
INSTALL a new TBC module. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.
------------------------------------------------- AD8 CHECK FOR VOLTAGE TO THE TRAILER TOW
CONNECTOR (DOES NOT OPERATE CORRECTLY)
- With the brake pedal released, measure the voltage between the trailer tow connector pin 3,
circuit CAT19 (BU), component side and ground.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 8901
- Is any voltage present?
Yes
GO to AD9.
No
The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility.
------------------------------------------------- AD9 CHECK CIRCUIT CAT19 (BU) FOR A SHORT TO
VOLTAGE
- Disconnect: TBC Module C238.
- Measure the voltage between the trailer tow connector pin 3, circuit CAT19 (BU), component side
and ground.
- Is any voltage present?
Yes
REPAIR the circuit. TEST the system for normal operation.
No
INSTALL a new TBC module. TEST the system for normal operation.
-------------------------------------------------
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 8905
Trailer Lighting Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 8906
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear > Page 8912
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear > Page 8913
Turn Signal Lamp: Diagrams Park/Turn Lamp, Left Front
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear > Page 8914
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear > Page 8915
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear > Page 8916
Turn Signal Lamp: Diagrams
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear > Page 8917
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear > Page 8918
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear > Page 8919
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear > Page 8920
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear > Page 8921
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear > Page 8922
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear > Page 8923
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear > Page 8924
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear > Page 8925
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear > Page 8926
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Rear > Page 8927
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations
Turn Signal Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 8931
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 8932
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 8933
Turn Signal Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 8934
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 8935
Turn Signal Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Removal and Installation
NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Remove the 2 screws and the steering column opening cover.
2. Remove the 3 screws and the upper and lower steering column shrouds.
3. Disconnect the multifunction switch electrical connector.
4. Remove the 2 multifunction switch screws and the multifunction switch.
- To install, tighten to 3 Nm (27 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp,
Left
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp,
Left > Page 8940
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 8946
Heated Glass Element Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 8947
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Page 8952
Heated Glass Element Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Page 8953
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Master Window Adjust Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Master Window Adjust Switch > Page 8959
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Master Window Adjust Switch > Page 8960
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Master Window Adjust Switch > Page 8961
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch
Power Window Switch: Diagrams Master Window Adjust Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 8964
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 8965
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 8966
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 8967
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > 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 (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 8970
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 8971
Power Window Switch: Testing and Inspection Window Adjust Switches - Passenger Side and
Rear Doors
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 8972
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 8973
Power Window Switch: Service and Repair
Window Control Switch
Removal and Installation
1. Remove the interior door handle cover.
2. Lift the window control switch bezel upward to release the clips.
3. Disconnect the window control switch electrical connectors from the window control switch.
4. Disconnect the window control switch from the window control switch bezel to remove.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Back Window Motor > Component
Information > Service and Repair
Back Window Motor: Service and Repair
Window Regulator Motor - Rear
Removal and Installation
NOTE: The power rear window 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. For additional information, refer to Window Regulator Rear See: Window Regulator/Back Window
Regulator/Service and Repair.
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 power rear window motor. For additional information, refer to Window Motor
Initialization - Rear See: Service and Repair/Window Motor Initialization - Rear.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door
Front Door Window Motor: Service and Repair Glass, Frames and Mechanisms - Exploded View,
Front Door
Glass, Frames and Mechanisms - Exploded View, Front Door
NOTE: LH shown, RH similar.
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 8983
Front Door Window Motor: Service and Repair Window Regulator Motor - Front Door
Window Regulator Motor - Front Door
Removal and Installation
NOTE: For LH front only, the front window motor must be initialized whenever the front window
motor is removed from the window regulator drum housing, a new window regulator is installed, a
new top run is installed or for any operation in which grease or lubricants are applied to the window
regulator or glass run.
1. Remove the front door window regulator. For additional information, refer to Window Regulator Front Door See: Window Regulator/Front
Door Window Regulator/Service and Repair/Window Regulator - Front Door.
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.
- For LH front window only, initialize the LH front window motor. For additional information, refer to
Window Motor Initialization - Front See: Service and Repair/Window Motor Initialization - Front.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door
Rear Door Window Motor: Service and Repair Glass, Frames and Mechanisms - Exploded View,
Rear Door
Glass, Frames and Mechanisms - Exploded View, Rear Door
NOTE: Explorer shown, Explorer Sport Trac similar.
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door > Page 8988
Rear Door Window Motor: Service and Repair Window Regulator Motor - Rear Door
Window Regulator Motor - Rear Door
Removal and Installation
1. Remove the interior moulding.
2. Remove the rear door trim panel and weather shield.
3. Remove the 3 window regulator motor bolts.
- To install, tighten to 7 Nm (62 lb-in).
4. Remove the window regulator motor.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Master Window Adjust Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Master Window Adjust Switch > Page 8993
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Master Window Adjust Switch > Page 8994
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Master Window Adjust Switch > Page 8995
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Master Window Adjust Switch
Power Window Switch: Diagrams Master Window Adjust Switch
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Master Window Adjust Switch > Page 8998
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Master Window Adjust Switch > Page 8999
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Master Window Adjust Switch > Page 9000
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Master Window Adjust Switch > Page 9001
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > 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 (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 9004
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 9005
Power Window Switch: Testing and Inspection Window Adjust Switches - Passenger Side and
Rear Doors
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 9006
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Page 9007
Power Window Switch: Service and Repair
Window Control Switch
Removal and Installation
1. Remove the interior door handle cover.
2. Lift the window control switch bezel upward to release the clips.
3. Disconnect the window control switch electrical connectors from the window control switch.
4. Disconnect the window control switch from the window control switch bezel to remove.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
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. NOTICE: 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Service and Repair > Window Glass - Rear, Fixed > Page 9013
Back Window Glass: Service and Repair Window Glass - Rear, Power
Window Glass - Rear, Power
Removal
NOTE: The power rear window 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.
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 rear window glass regulator. For additional information, refer to Window Regulator Rear See: Window Regulator/Back Window
Regulator/Service and Repair.
2. Remove both C-pillar upper trim panels.
3. Remove the 12 rear window glass mounting nuts.
4. NOTICE: 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.
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Service and Repair > Window Glass - Rear, Fixed > Page 9014
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. For additional information, refer to Window Regulator Rear See: Window Regulator/Back Window
Regulator/Service and Repair. Initialize the power rear window motor. For additional information, refer to Window Motor
Initialization - Rear See: Service and Repair/Window Motor Initialization - Rear.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door
Window Glass Weatherstrip > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded
View, Front Door
Front Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Front Door
Glass, Frames and Mechanisms - Exploded View, Front Door
NOTE: LH shown, RH similar.
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door
Window Glass Weatherstrip > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded
View, Front Door > Page 9020
Front Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Front
Door Glass Top Run - Front
Removal and Installation
NOTE: For LH front only, the front window motor must be initialized whenever the front window
motor is removed from the window regulator drum housing, a new window regulator is installed, a
new top run is installed or for any operation in which grease or lubricants are applied to the window
regulator or glass run.
1. Remove the front door window glass. For additional information, refer to Window Glass - Front
Door See: Service and Repair/Window Glass Front Door.
2. Remove the exterior moulding.
3. Remove the front door glass top run channel assembly bolt.
- To install, tighten to 12 Nm (106 lb-in).
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.
- For LH front window only, initialize the LH front window motor. For additional information, refer to
Window Motor Initialization - Front See: Service and Repair/Window Motor Initialization - Front.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
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.
Remove the liftgate window glass struts.
- To avoid breaking the liftgate window glass, disconnect the liftgate window glass struts from the
liftgate window glass before disconnecting the liftgate window glass struts from the rear liftgate.
5. Remove the 2 liftgate hinge-to-glass screws.
- Apply threadlock into the liftgate window glass hinge-to-glass bolt hole, making sure that the
threadlock is on the threads.
- To install, tighten to 10 Nm (89 lb-in).
6. With the help of an assistant, remove the liftgate window glass.
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
NOTE: LH shown, RH similar.
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. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
instruction may result in serious personal injury.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair > Page 9027
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.
NOTICE: 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 Deluxe Windshield Removal 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.
NOTE: Lubricate the urethane adhesive with water to aid the Deluxe Windshield Removal Tool
when cutting the urethane adhesive.
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.
NOTE: Support the glass to prevent the glass from dropping while cutting the urethane adhesive.
Using the Deluxe Windshield Removal Tool, cut the urethane adhesive from the quarter window
glass starting at the upper center of the quarter window glass and working toward the bottom
corners.
5. Using the Deluxe Windshield Removal Tool, cut the remaining urethane adhesive and carefully
remove the quarter glass from the vehicle and
place on a stable work surface.
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. Repair all minor scratches or exposed metal on the pinch
weld following manufacturer's instructions. Use the same brand pinch weld primer, glass primer
and urethane adhesive.
Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm (0.04 in to 0.08 in)
base of original equipment urethane adhesive 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 adhesive. Remove any foreign
material or water that may have entered during glass removal.
5. If reinstalling the original quarter window glass, remove the excess urethane adhesive from the
glass leaving a thin layer to bond with the new
urethane adhesive 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 urethane adhesive and
glass primer. Do not mix different brands of urethane
adhesive and glass primer. Refer to the Material Chart in this procedure.
If installing a new rear quarter window glass, apply glass primer according to manufacturer's
instructions. Allow at least 6 minutes to dry.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair > Page 9028
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
adhesive with less effort and continuous bead.
NOTE: The rear 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 there are no gaps in the urethane bead.
10. WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane
adhesive manufacturer's curing directions.
Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention.
Failure to follow these instructions may result in serious injury to vehicle occupant(s).
NOTICE: Before positioning the quarter window glass, open vehicle windows to prevent the air
pressure of closing doors from affecting the urethane 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 (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door
Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear
Rear Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Rear
Door Glass Top Run - Rear
Removal and Installation
1. Remove the rear door window glass. For additional information, refer to Window Glass - Rear
Door See: Service and Repair/Window Glass Rear Door.
2. Remove the exterior moulding.
3. Remove the rear door glass top run assembly bolt.
- To install, tighten to 12 Nm (106 lb-in).
4. Remove the rear door glass top run channel assembly.
- Remove the rear door glass top run channel assembly through the top opening of the rear door.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door
Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear > Page 9034
Rear Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Rear Door
Glass, Frames and Mechanisms - Exploded View, Rear Door
NOTE: Explorer shown, Explorer Sport Trac similar.
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Removal and Installation
NOTE: The power rear window 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.
- 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 (97 lb-in).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component
Information > Service and Repair > Page 9039
8. Disconnect the electrical connector.
9. Remove the window regulator.
10. To install, reverse the removal procedure.
- Initialize the power rear window motor. For additional information, refer to Window Motor
Initialization - Rear See: Service and Repair/Window Motor Initialization - Rear.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door
Front Door Window Regulator: Service and Repair Glass, Frames and Mechanisms - Exploded
View, Front Door
Glass, Frames and Mechanisms - Exploded View, Front Door
NOTE: LH shown, RH similar.
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 9044
Front Door Window Regulator: Service and Repair Window Regulator - Front Door
Window Regulator - Front Door
Removal and Installation
NOTE: For LH front only, the front window motor must be initialized whenever the front window
motor is removed from the window regulator drum housing, a new window regulator is installed, a
new top run is installed or for any operation in which grease or lubricants are applied to the window
regulator or glass run.
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. NOTICE: 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.
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.
- For LH front window only, initialize the LH front window motor. For additional information, refer to
Window Motor Initialization - Front See: Service and Repair/Window Motor Initialization - Front.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door
Rear Door Window Regulator: Service and Repair Glass, Frames and Mechanisms - Exploded
View, Rear Door
Glass, Frames and Mechanisms - Exploded View, Rear Door
NOTE: Explorer shown, Explorer Sport Trac similar.
1. For additional information, refer to the procedures.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door > Page 9049
Rear Door Window Regulator: Service and Repair Window Regulator - Rear Door
Window Regulator - Rear Door
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. NOTICE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield
Glass
Windshield: Service and Repair Windshield Glass
Windshield Glass
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield
Glass > Page 9054
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.
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. 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.
NOTICE: 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 Deluxe Windshield Removal 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.
NOTE: Lubricate the urethane adhesive with water to aid the Deluxe Windshield Removal Tool
when cutting the urethane adhesive.
NOTE: Support the windshield glass to prevent the glass from dropping while cutting the urethane
adhesive.
Using the Deluxe Windshield Removal Tool, cut the urethane adhesive from the windshield glass
starting at the upper center of the windshield glass and working toward the bottom corners.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield
Glass > Page 9055
11. Using The Pumper, distance the windshield from the body.
12. Using the Deluxe Windshield Removal Tool, cut the remaining urethane adhesive.
13. NOTE: Removing the windshield glass requires more than one technician.
NOTE: If reinstalling the windshield glass, tape the windshield at the windshield stops to aid in
alignment of the glass during installation.
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 adhesive 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. Repair all minor scratches or exposed metal on the pinch
weld following manufacturer's instructions. Use the same brand pinchweld primer, glass primer and
urethane adhesive.
Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm (0.04 in to 0.08 in)
base of original equipment urethane adhesive on the pinch weld.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield
Glass > Page 9056
5. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the
existing urethane adhesive. Remove any foreign
material or water that may have entered during windshield removal.
6. If installing the original windshield glass, remove the excess urethane adhesive from the glass
leaving a thin layer to bond with the new urethane
adhesive 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 urethane adhesive and
glass primer. Do not mix different brands of urethane
adhesive and glass primer. Refer to the Material Chart in this procedure.
If installing a new windshield glass, apply glass primer according to manufacturer's instructions.
Allow at least 6 minutes to dry.
9. Cut the urethane adhesive applicator tip to specification.
10. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the
urethane adhesive with less effort and continuous bead.
NOTE: 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 adhesive bead
on the pinch weld, starting and ending at the bottom of the windshield near the center, making sure
there are no gaps in the bead.
11. WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane
adhesive manufacturer's curing directions.
Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention.
Failure to follow these instructions may result in serious injury to vehicle occupant(s).
NOTICE: Before positioning the windshield glass, open vehicle windows to prevent the air pressure
of closing doors from affecting the urethane 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield
Glass > Page 9057
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 (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield
Glass > Page 9058
Windshield: Service and Repair Glass Reseal - Windshield
Glass Reseal - Windshield
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 adhesive 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 adhesive applicator tip to specification.
9. NOTE: Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane
adhesive with less effort and a continuous bead.
NOTE: 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 adhesive 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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield
Glass > Page 9059
16. Install the RH and LH side A-pillar trim panels.
17. Clean the exterior and interior of the windshield glass with glass cleaner.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Locations > Page 9065
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Locations > Page 9069
Wiper Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Locations > Page 9070
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations > Page 9075
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations > Page 9076
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations
Windshield Washer Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 9080
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 9081
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
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 9084
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 9085
Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 9086
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Page 9087
Windshield Washer Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Removal and Installation
NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Remove the 2 screws and the steering column opening cover.
2. Remove the 3 screws and the upper and lower steering column shrouds.
3. Disconnect the multifunction switch electrical connector.
4. Remove the 2 multifunction switch screws and the multifunction switch.
- To install, tighten to 3 Nm (27 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations
Wiper Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 9091
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 9092
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 9095
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 9096
Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 9097
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Page 9098
Wiper Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Removal and Installation
NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Remove the 2 screws and the steering column opening cover.
2. Remove the 3 screws and the upper and lower steering column shrouds.
3. Disconnect the multifunction switch electrical connector.
4. Remove the 2 multifunction switch screws and the multifunction switch.
- To install, tighten to 3 Nm (27 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations
Washer Fluid Level Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations
> Page 9102
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations
> Page 9103
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations >
Two-Way Washer Pump Motor > Page 9108
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations >
Two-Way Washer Pump Motor > Page 9109
Windshield Washer Motor: Locations Washer Pump Motor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations >
Two-Way Washer Pump Motor > Page 9110
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams >
Washer Pump Motor
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams >
Washer Pump Motor > Page 9113
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service
and Repair
Windshield Washer Pump: Service and Repair
Washer Pump
Removal and Installation
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. For additional information, consult the product Material Safety Data Sheet (MSDS) if
available. 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.
4. NOTE: When servicing the windshield washer pump, be careful not to damage the windshield
washer pump seal.
Remove the windshield washer pump.
5. NOTICE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
and Repair
Windshield Washer Reservoir: Service and Repair
Washer Reservoir
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the Air Cleaner (ACL) assembly.
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.
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. For additional information, consult the product Material
Safety Data Sheet (MSDS) if available. 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).
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
and Repair > Page 9120
8. Remove the side bolt.
- To install, tighten to 5 Nm (44 lb-in).
9. Remove the bolt.
- To install, tighten to 5 Nm (44 lb-in).
10. Remove the windshield washer pump reservoir.
11. NOTICE: When servicing the windshield washer pump, be careful not to damage the
windshield washer pump seal.
Transfer components as necessary.
12. NOTICE: 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 (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
Windshield Washer Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Page 9124
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Page 9125
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection > Multifunction Switch > Page 9128
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection > Multifunction Switch > Page 9129
Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection > Multifunction Switch > Page 9130
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection > Page 9131
Windshield Washer Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Removal and Installation
NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Remove the 2 screws and the steering column opening cover.
2. Remove the 3 screws and the upper and lower steering column shrouds.
3. Disconnect the multifunction switch electrical connector.
4. Remove the 2 multifunction switch screws and the multifunction switch.
- To install, tighten to 3 Nm (27 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 that the RH and LH wiper blades are located at the specified position.
3. 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 (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Pivot Arm - Front
Wiper Arm: Service and Repair Wiper Pivot Arm - Front
Wiper Pivot Arm - Front
1. Remove the wiper pivot arm.
1. Pull up on the pivot arm.
2. Pull out on the retaining tab and remove the pivot arm.
2. NOTE: The windshield wiper motor must be cycled to make sure that it is in the park position. If
necessary, adjust the wiper pivot arms. For
additional information, refer to Wiper Blade and Pivot Arm Adjustment - Windshield See:
Adjustments.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Pivot Arm - Front > Page 9137
Wiper Arm: Service and Repair Wiper Pivot Arm - Rear
Wiper Pivot Arm - Rear
Removal
1. Remove the wiper pivot arm cover.
2. Remove the wiper pivot arm.
1. Remove the pivot arm nut.
2. Remove the wiper pivot arm.
Installation
1. NOTE: Before installation, be sure that the rear window wiper motor is in the park position.
Turn the wiper switch ON and OFF to allow the rear window wiper motor to cycle and stop in the
park position.
2. Position the wiper pivot arm.
3. Install the pivot arm nut.
- Tighten to 17 Nm (150 lb-in).
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.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Pivot Arm - Front > Page 9138
If the pivot arm is not in the correct position, remove the pivot arm and repeat Steps 1 through 4.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations >
Page 9142
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations
Wiper Motor: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 9146
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 9147
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Wiper Motor - Windshield
Wiper Motor: Service and Repair Wiper Motor - Windshield
Wiper Motor - Windshield
Removal and Installation
NOTE: A new wiper motor assembly comes with the linkage arm installed.
1. Remove the front wiper pivot arms. For additional information, refer to Wiper Pivot Arm - Front
See: Wiper Arm/Service and Repair/Wiper Pivot
Arm - Front.
2. NOTICE: To avoid breaking the retaining clips on the cowl panel, do not pull up on the rear of
the cowl panel.
Pry up on the front of the cowl panels to release it from the retaining clips.
3. Remove the cowl panel grilles.
4. Disconnect the windshield wiper motor electrical connector.
- Unclip the wiring harness from the wiper arm.
- Position the wiring harness aside.
5. Remove the 3 windshield wiper assembly mounting bolts.
- To install, tighten to 15 Nm (133 lb-in).
6. Remove the windshield wiper assembly and position on a workbench.
7. NOTICE: 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 (133 lb-in).
9. Remove the windshield wiper motor.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Wiper Motor - Windshield > Page 9150
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 (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Wiper Motor - Windshield > Page 9151
Wiper Motor: Service and Repair Wiper Motor - Rear Window
Wiper Motor - Rear Window
Removal and Installation
1. Remove the rear wiper pivot arm. For additional information, refer to Wiper Pivot Arm - Rear
See: Wiper Arm/Service and Repair/Wiper Pivot
Arm - Rear.
2. Remove the rear window wiper motor grommet.
1. Remove the pivot shaft nut.
- To install, tighten to 10 Nm (89 lb-in).
2. Remove the grommet.
3. Open the liftgate window.
4. Remove the wiper motor cover trim panel.
5. Remove the rear window wiper motor.
1. Disconnect the electrical connectors.
2. Remove the 2 rear window wiper motor nuts.
- To install, tighten to 6 Nm (53 lb-in).
3. Remove the rear window wiper motor.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 9155
Wiper Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 9156
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations
Wiper Switch: Locations
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9160
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9161
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
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 (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection
> Multifunction Switch > Page 9164
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection
> Multifunction Switch > Page 9165
Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer 2wd Workshop Manual (V6-4.0L (2009))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection
> Multifunction Switch > Page 9166